THERMPROCESS SPECIAL - heat processing · Hallen/Halls 15 –17 Modell, Form- und Kernherstellung/...

ISSN 1611-616X

02 I 2019

Vulkan-Verlag

International Magazine for Industrial Furnaces Heat Treatment & Equipment

www.heat-processing.com

THERMPROCESS SPECIALAll about the biggest trade fair in the industry – Products, Trends, Markets and Timetable

CHAMPAGNE RECEPTION

Get-together at the THERMPROCESS

Meet the heat processing community on Wednesday, 26 June 2019 at 5 p.m.

Vulkan Verlag cordially invites authors, readers and business partners to an informal get-together at the THERMPROCESS 2019 in Düsseldorf.

The focus: the latest publications, industry news and just exchanging ideas, opinions and experience in a relaxed atmosphere with contacts and colleagues.

We look forward to seeing you at Booth A24 in Hall 9.

Please register until 07 June 2019

Sina Ruhwedelphone: +49 201 82002 91email: [email protected]

COMPETENCE in

THERMOPROCESSING TECHNOLOGY

EDITORIAL

Friedrich-Georg KehrerGlobal Portfolio Director

Metals and Flow Technologies Messe Düsseldorf GmbH

THERMPROCESS is a “must attend event“ for the industry

With more than 2,100 exhibitors from all over the world, the upcoming “Bright World of Metals” continues the

success of the previous event four years ago, confirming the dominance of the four leading international trade fairs – GIFA, METEC, THERMPROCESS and NEWCAST – for the foundry industry and metallurgical industry. Exhibitors will present the entire spectrum of foundry technology, cast products, metallurgy and thermal process technology across twelve exhibition halls. The list of participating nations is global and ranges from “A” like Australia to “U” like United Arab Emirates. The international reach will be correspon-dingly broad this year as well. More than half of the expected 78,000 trade visitors traditionally travel from overseas and Europe to Düsseldorf, the world capital of the “Bright World of Metals”.

With more than 330 exhibitors from more than 30 coun-tries, THERMPROCESS, the 12th International Trade Fair and Symposium for thermoprocess technology, is booked up for the first time in its 45-year history. By far the largest exhibitor nation is Germany, followed by Italy, India, UK and China. The longest route has been taken by an exhibitor from Australia.

Real added value is also provided by the technical sup-porting program; here, theory and practice go hand in hand. As part of the FOGI special show – organized by the Forschungsgemeinschaft Industrieofenbau e.V. in the VDMA – nine German research institutes are presenting current projects and work priorities. One highlight will certainly be the podium discussion on the first day of the fair

on “The Paris climate targets 2050 and their significance for mechanical and plant engineering”. And last but not least, there is the VDMA Metallurgy THERMPROCESS Symposium with presentations on topics such as “Innovative plant concepts for heat treatment”, “New burner technologies” or “Energy efficiency and emission reduction”. The two-day specialist forum “Thermal Energy Storage”, which focuses on material development and the role of thermal storage in future energy systems, will be held for the first time.

To put it in a nutshell: THERMPROCESS 2019 from 25 to 29 June in Düsseldorf is a “must attend event” for the entire industry.

This issue of heat processing magazine sets a special focus on the THERMPROCESS trade fair, including a big Special on this occasion on the following pages. It will hopefully help you to prepare yourself properly and give you everything you need to make the best out of your trade fair visit.

See you in Düsseldorf!

232-2019 heat processing

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EDITORIAL

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TABLE OF CONTENTS

THERMPROCESS 2019 – Special 23 Editorial: Friedrich-Georg Kehrer, Messe Düsseldorf

26 General Information

28 Basic Data

29 Interview: Dr. Peter Schobesberger, Aichelin Holding GmbH

30 Site Plan

32 Congresses with timetable

36 Interview: Roberto Pancaldi, Tenova Metals

38 THERMPROCESS Symposium

40 FOGI Special Show

41 ecoMetals Trails

42 Markets: Trends – E-Mobility, Digitization and Sustainability

44 Interview: Dr. Marco Rische, ABP Induction Systems GmbH

45 Product Preview

50 Interview: Philippe Cruiziat, Fives’ Steel

60 Interview: William Disler, AFC-Holcroft L.L.C.

72 Interview: Sławomir Woźniak, Seco/Warwick S.A.

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Eingang Ost/Entrance East

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Messe Düsseldorf GmbH

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

Tel. +49 211 4560-01 _ Fax +49 211 4560-668

www.messe-duesseldorf.de

The Bright World of Metals25 – 29 JUNE 2019

CCD Ost/CCD Süd Kongresse/Congresses

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Eingang Süd II/Halle 17Entrance South II/Hall 17

Halle/Hall 12Gießereichemie/Chemical materials for foundries

Halle/Hall 11Druckguss und Peripherie/Die casting and peripheral equipment

Hallen/Halls 15 – 17Gießereimaschinen und Anlagen/Foundry machines and foundry plants

Halle/Hall 13Additive Manufacturing/Additive manufacturing

Halle/Hall 12Anschnitt und Speisertechnik/Gating and feeding

Hallen/Halls 15 – 17Modell, Form- und Kernherstellung/Moulding, pattern and core making

METEC THEMENSCHWERPUNKTE/ METEC MAIN TOPICS

GIFA THEMENSCHWERPUNKTE/GIFA MAIN TOPICS

Halle/Hall 3Schmiedetechnik/Forging

Hallen/Halls 10–1315–17

Hallen/Halls 3 + 4 + 5

Hallen/Halls 9 + 10

Hallen/Halls 13 + 14

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30 SITE PLAN 45 PRODUCT PREVIEW

Hotspot of the metallurgical industry: GMTN 2019

As the leading trade fairs in their respective sectors, GIFA, METEC, THERMPROCESS and NEWCAST will be covering

the most important trends – and that is not all: they will be driving forces behind the ongoing market development of key technologies, above all in the core areas of Additive Manufacturing and Industry 4.0 or with respect to the tremendous potential offered by lightweight structures in the automotive industry.

The exhibitors will present the entire spectrum of foundry technology, castings, metallurgy and thermo process technology in twelve different halls. The list of countries participating is global, as trade visitors from the business, research, development and academic communities can-not obtain such a comprehensive insight into the industry at any other trade fair anywhere in the world. So the international reach of the four trade fairs will once again be impressively broad this year. It is traditionally the case that more than half of the 78,000 trade visitors that are expected to attend come to Düsseldorf from overseas and from European countries.

FOUR TRADE FAIRS UNDER ONE ROOFGIFA, METEC, THERMPROCESS and NEWCAST are inde-pendent trade fairs that each individually stands for itself and its markets, while they together make up the com-plete picture presented by the “Bright World of Metals”. GIFA, the International Foundry Trade Fair and Technical Forum, has been the heart of the foundry industry for decades. About 900 exhibitors from 47 countries so far will be presenting their products and services in Halls 10 to 13 and 15 to 17. They include such world market leaders as Bühler AG (Switzerland), ASK Chemicals GmbH (Germany), Foseco (Germany), Hüttenes Albertus (Germany), Loramendi S. Coop (Spain) und Vesuvius GmbH (Germany). There will also be large joint stands again from China and Italy.

NEWCAST: FULLY BOOKED ON ITS ANNIVERSARYNEWCAST, the 5th International Trade Fair for Castings with the Newcast Forum, is fully booked on its anniver-sary. Some 400 exhibitors from more than 30 different countries will be demonstrating in Halls 13 and 14 how global the production of castings has become. Market leaders like Finoba Automotive GmbH (Germany), GOM GmbH (Germany), Gießerei Heunisch (Germany), Eisen-werk Brühl (Germany), Kimura Foundry Co. Ltd. (Japan), Kutes Metal Inc. (Turkey) und Waupaca Foundry (USA) are taking advantage of this platform. The Fraunhofer

Institute for Manufacturing Technology and Advanced Materials/IFAM (Germany) will also be represented. The foundry associations from Croatia, Mexico and Hungary will be at NEWCAST for the first time.

METEC 2019: NEW RECORD ON ITS 10TH ANNIVERSARYMETEC, the 10th International Metallurgical Trade Fair, is home to the large plant manufacturers. Suppliers of equip-ment for iron, steel and non-ferrous metal production, for casting, pouring and shaping steel as well as rolling mills and steel mills will have particular impressive displays. METEC is setting a new record for the number of exhibitors this year, with more than 530 companies from 34 countries so far, and is the undisputed leader among trade fairs for its industry. The list of exhibitors includes: Inteco (Austria), Primetals Technologies Ltd. (UK), RHI Magnesita (Austria), SMS Group (Germany) und Tenova S.P.A. (Italy). Forged com-ponents will be on show at METEC for the first time, too. In the past, they were part of NEWCAST, but the increase in their significance makes the METEC a better place to exhibit them.

INDUSTRY LEADERS AT THERMPROCESSWith foreign participation amounting to 50 % and about 300 exhibitors, THERMPROCESS, the 12th International Trade Fair and Symposium for Thermo Process Techno-logy, is a must for international equipment suppliers. This is reflected in the list of exhibitors that have registered so far, which includes many of the industry leaders: Aichelin Holding GmbH (Germany), Ajax Tocco Magnethermic GmbH (Germany), Andritz Maerz GmbH (Germany), Honeywell Thermal Solutions (Germany), Inductotherm Group (USA) and ITG Induktionsanlagen GmbH (Germany) will be highlighting technological trends relating to indus-trial furnaces, industrial heat treatment plants and thermal processes for precious metals, hard metals, ceramics, steel and iron, components and equipment as well as other supplies.

DOMINANT ISSUE AT THE “BRIGHT WORLD OF METALS”Digital transformation is an important topic at the “Bright World of Metals”, because Industry 4.0 is one of the main developments determining the future in the metallur-gical sectors too, so it will be a dominant issue in the halls on the exhibition site in Düsseldorf. More and more sophisti cated sensor technology is providing more and more data from the production process in foundries and


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GENERAL INFORMATION


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GENERAL INFORMATION

steel mills. Thousands of data are needed for every slab that is cast and every strip of steel that is rolled. It is no longer possible to analyze these data, to recognize patterns and to obtain information from them with the classic IT methods. The computer centres and databases of the past are being replaced by big data analysis, artificial intelligence and networked cloud systems. The digital monitoring of machines and equipment reduces main-tenance costs, increases efficiency and has the potential to optimize products.

MAJOR FOCUS: ADDITIVE MANUFACTURINGThe “Bright World of Metals” is spotlighting another topical subject: Additive Manufacturing – the big issue in production engineering. The special Additive Manufacturing show in

Hall 3 and the “Metal 3D Printing” conference will, for example, be premiered on 26 June. AM is already in successful opera-tion in many demanding industries like medical engineering, car manufacturing and aerospace. The foundry, steel and aluminium industry have recognized the potential of 3D printing too – as, not least of all, a survey by the Federal Association of the German Foundry Industry (BDG) about the impact of electromobility on the foundry industry and its products emphasises. Alternative concepts implemented in hybrid and electric drives require increasing casting volumes by comparison with drives based exclusively on combustion engines. It is likely that peak casting demand will not be reached until 2030, according to the BDG survey – so the prospects for GIFA and METEC 2019 are excellent.

For further Information please visit: www.tbwom.com

THERMPROCESS 2019 – Basic Data

SHOW VENUEDüsseldorf FairgroundStockumer Kirchstraße 6140474 DüsseldorfGermany

Address for car navigation system: Am Staad (Stockumer Höfe), 40474 Düsseldorf

Halls 9–10

OPENING HOURS25–28 June, daily: 10 am to 6 pm29 June 2019: 10 am to 4 pm

TICKETS1-day-ticket: € 64.00 on-site € 45.00 onlineSeason ticket: € 130.00 on-site € 100.00 online1-day-ticket for students: € 18.00 only on-site (Please bring the corresponding legitimation)

The e-ticket entitles the holder to use the VRR public transport system free of charge

MAIN PRODUCT CATEGORIES ■ Industrial furnaces, industrial heat treatment

plants and thermal processes ■ Equipment for special applications ■ Components, equipment and other supplies ■ Occupational safety and ergonomics ■ Consulting, design, services and engineering ■ Trade associations, specialized publishers

and magazines ■ Training and education

PROGRAMMEFOGI Special Show:25–29 June, Hall 10, Booth F18THERMPROCESS Symposium:25–29 June, Hall 9, Booth D74

ORGANIZERMesse Düsseldorf GmbHMesseplatz 140474 Düsseldorf, Germany+49 (0)211 / 4560-01

FURTHER INFORMATIONwww.thermprocess-online.com


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“There is considerable investment restraint in Europe”Dr. Peter Schobesberger, CEO of Aichelin Holding GmbH Here you can find Aichelin: Hall 9, Booth E26

What is the significance of THERMPROCESS for your company?Schobesberger: With our production sites in Europe, Asia, and North America, THERMPROCESS is the most important international fair for Aichelin Group. We will meet inter-national specialists to whom we can present our most recent developments and discuss important trends.

Which products will you present to the visitors in Düsseldorf?Schobesberger: Without revealing too much, let me tell you that we will, among other things, present new develop ments that will be able to reduce emissions of plants considerably; moreover, we will be starting a new chapter in the maintenance of thermal processing plants by using Industry 4.0 solutions. We are looking forward to presenting these new solutions to all stakeholders.

What are the trends and technologies that will shape the industry in the future?Schobesberger: The thermal processing technology is closely intertwined with production processes. This is about the digitization of thermal processing plants and their communication with other components of the factory, something everyone’s been talking about recently. What’s interesting is the change in our customers’ produc-tion portfolios, where we expect all kinds of very different developments with the increased use of electro mobility and hybrid technologies.

Do you expect new business at the fair?Schobesberger: We would not take part in a fair if we did not expect business prospects. Thanks to the profes sional advice available at fairs, projects emerge quite often, which then bring success a few months later. And this is what we expect this year, too.

How would you assess the current economic situation?Schobesberger: For the thermal processing industry, the current economic situation is rather difficult. There is consi derable investment restraint in Europe at the moment. Reasons for this can likely be found in the automotive industry which suffers from the international trade dis-putes and in parts also from unrealistic expectations from e-mobility. The situation is slightly better in Asia and North America, though the markets are subject to the same uncertainties.


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INTERVIEW

Visit us at THERMPROCESS 2019

Vulkan-Verlag GmbHHall 9 / Booth A2425-29 June 2019, Messe Düsseldorf

Thermoprocessing Technologies


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SITE PLAN

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FOCUS ON Edition 27

From 3D printing to digitization and climate protection – extensive programme at GMTN 2019

The “Bright World of Metals” from 25 to 29 June 2019 will be featuring a unique range of international congresses,

symposiums, forums and special shows. The four trade fairs GIFA, NEWCAST, METEC and THERMPROCESS will provide a high-quality programme focusing on the entire spectrum of foundry technology, castings, metallurgy and thermo process technology – including additive manufacturing, metallurgical issues, trends in the steel industry, current aspects of thermo process technology or innovations in the energy and resource efficiency fields. Some of the events will be taking place for the first time too, such as the two-day thermal energy storage forum, the one-day congress about metal 3D printing or the special “additive manufacturing” and “digitisation & climate protection” shows.

THERMAL ENERGY STORAGE FORUMFor the first time, experts from the research, development and industrial communities will be meeting at the Rhein-hotel “Vier Jahreszeiten” in Meerbusch (Düsseldorf) for the thermal energy storage forum on the occasion of the “Bright World of Metals”. The two-day programme (24 and 25 June) revolves around such relevant topics as material development and the role thermal storage equipment will be playing in future energy systems in relation to metal manufacturing and processing. Major emphases of the programme are:

■ “Use of waste heat by thermal energy storage units”. ■ “Power-to-heat-to-power, Carnot batteries, high-tem-

perature storage”. ■ “Chemical reactions for the storage of thermal energy”. ■ Panel discussion: “Thermal storage in industrial

processes”.

ZAE Bayern (Bavarian Centre of Applied Energy Research) and the German Energy Storage Association are behind the event, which is being organized by Messe Düsseldorf together with the ENERGY STORAGE EUROPE team and the GIFA, METEC, THERMPROCESS and GIFA teams.

ADDITIVE MANUFACTURING: CONGRESS & SPECIAL SHOWTwo events about Additive Manufacturing will be experi-encing their premiere: the special show in Hall 13 and the “Metal 3D Printing” conference. Additive Manufacturing is creating new potential for foundries and their suppliers in model and mould production, in core manufacturing or in direct metal printing. The presentations at the conference on 26. June will be covering the following central topics:

■ How foundries benefit from 3D printing ■ 3D printing in tool and mould production ■ Processing of zinc die-casting materials in 3D printing ■ New hybrid manufacturing chains – casting/generation.

The congress speakers include such 3D specialists as Christoph Dörr/Trumpf, Matthias Steinbusch/Voxeljet or Ralf Frohwerk/SLM Solutions Group. The conference manager and host is Sebastian Bremen, head of the 3D Printing Centre in Aachen and Group Manager Laser Powder Bed Fusion, Fraunhofer ILT. The conference will be rounded off by a guided tour of GIFA Hall 13, including the special AM show.

GIFA & NEWCASTThe international foundry industry is concentrated in the GIFA and NEWCAST Halls 10 to 17 – not least of all because of the wide-ranging activities of the Association


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CONGRESSES

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of German Foundry Experts and the Federal Association of the German Foundry Industry. The special “digitisation & climate protection” show will be holding its premiere, for example. The potential for using waste heat, most of which is still not utilized, provides foundries with parti-cularly large opportunities to reduce energy costs and CO2 emissions – another reason to tackle this issue. The meeting point for foundries in Hall 13 (Stand D04) has also been redesigned, with its sections devoted to different subjects being the main attractions (e.g. “Technology in casting”, “World of castings”). The NEWCAST Award on 26 June is not a premiere, but it is a genuine highlight. This is where tribute is paid to innovative castings from NEWCAST exhibitors.

METEC & EMC & ESTADMETEC with the associated congresses EMC – European Metallurgical Conference and ESTAD – European Steel Technology and Application Days is an unbeatable three-part success story. From 24 to 28 June, everything at ESTAD will focus on steel as a material, its production and applications as well as environmental engineering and energy aspects. The five-day congress is an absolute must for steel manufacturers, suppliers and users. The 4th ESTAD is being organized by the steel institute VDEh in co-operation with its partners “Austrian Society for

Metallurgy and Materials“ and “Associazione Italiana di Metallurgia“.

Not only METEC is taking place for the tenth time – EMC is celebrating its tenth anniversary next year too. The European Metallurgical Conference is the most impor-tant conference for non-ferrous metallurgy in Europe and starts two days before METEC. The main issue on which it focusses is optimum utilisation of resources and recycling for a sustainable solution. The conference is being held exclusively in English, is organized by GDMB – Society of Metallurgists and Miners and is aimed at metal producers, plant manufacturers, service providers, universities and engineering firms.

THERMPROCESS WITH A SYMPOSIUM AND SPECIAL SHOWTheory and practice also go hand in hand at the two THERMPROCESS events, the special FOGI show organized by the VDMA Industrial Furnace Manufacturing Research Association and the THERMPROCESS Symposium, for which VDMA Metallurgy is responsible. The Symposium deals with current aspects of thermo process technology in numerous lectures. In addition to the lectures, promi nent research institutes from the thermo process techno logy field are presenting their areas of operation and latest research projects in the special FOGI show in Hall 10.


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TIMETABLE

SonntagSunday23.06.2019

MontagMonday24.06.2019

DienstagTuesday25.06.2019

MittwochWednesday26.06.2019

DonnerstagThursday27.06.2019

FreitagFriday28.06.2019

SamstagSaturday29.06.2019

GIFA-Forum (International) GIFA Forum (International)

Instituteschau – Straße der Wissenschaft Institute Show – Road of Science

NEWCAST-Forum NEWCAST Forum

Technik in Guss+ World of Casting Technology in casting + World of Casting

THERMPROCESS-Symposium THERMPROCESS Symposium

FOGI-Sonderschau FOGI Special Show

EMC 2019 European Metallurgical Conference

1. Fachkonferenz Metall – 3D-Druck1st Conference Metal – 3D Printing

NEWCAST-Award NEWCAST Award

6. DGFS-Fachtagung 6th DGFS Trade Symposium

4th ESTAD 2019, European Steel Technology and Application Days

FTE Fachforum Thermische EnergiespeicherFTE Special Forum Thermal Energy Storage

Rahmenprogramm/Ancillary programmeZeitplan/Timetable

FOCUS ON Edition 27

“Innovation is a challenge to be taken on with other players of the industry”Roberto Pancaldi, CEO of Tenova Metals Here you can find Tenova: Hall 4, Booth A21

How important are the trade fairs METEC and THERM-PROCESS for your company?Pancaldi: Our participation will be a great occasion not only to interact with the key players, but also to gain insights into future developments of the market. These fairs represent a unique opportunity for us. In particular, we will be present at METEC, where all Tenova Metals technologies will be presented. Our experts will be involved in METEC’s ESTAD Conference and in THERMPROCESS Symposium to present our solutions through several papers.

What products will you present in Düsseldorf?Pancaldi: Our booth gives a comprehensive insight into all Tenova Metals technologies, highlighting the specific strengths of our business units. This is the meaning of our Arena, a dedicated space where our products will be presented during the exhibition. The improvements in our portfolios and the fostered connection with our clients developed through digital technologies, such as predictive maintenance, remote assistance and artificial intelligence, will be also part of the program at the Arena.

Two pieces of equipment will be displayed: Pomini Digital Texturing (PDT) and Tenova Self Regenerative Burner (TRGS). In the field of cold rolling, roll texturing is of utmost importance to achieve the correct surface quality on the metal sheet, to grant the highest perfor-

mance in terms of paintability and formability. PDT is our new disruptive technology solution for the

roll texturing market, and thanks to augmented reality, our visitors will experience the capability of our texturing machine applied to a roll, physi-cally displayed at our booth.

In reheating and heat treating, the smart burner TRGS, is an example of the interaction of the best available technologies (BAT) with digital optimization. The machines are in fact enhanced

by the enabling technologies of Industry 4.0, to increase heat process efficiency

and to collect data to pre-vent failures and to deploy predictive maintenance.

What trends and technologies are shaping the industry?Pancaldi: Circular economy and digital transformation are the two ‘mantra’ that we keep on hearing in all manufacturing industries, as they are two of the main pillars of the new sustain-able economic model towards which all global mega trends – from demographic shifts to climate change – are driving.

However, I would not say that this has radically changed the way we work in Tenova: sustainability and innovation are in our DNA, and we have always strived to design solutions that consume less energy, valorize the residual directly inside the production cycle or in an industrial symbiosis approach, increasing the overall facility efficiency. Surely, we are now taking a step forward towards the development of new integrated business models by applying the principles of Industry 4.0 and circular economy.

I would like to mention some of the latest technologies we have been working on: One is in the direction of decarboni-zation of steel production, replacing carbon partially or totally with hydrogen as reducing agent of the Direct Reduction (DR) process. We have already two ongoing pilot projects implementing this technology in Europe. One is SALCOS® (SAlzgitter Low CO2 Steelmaking), a concept for a CO2- reduced steel production, created with Salzgitter AG. For this project we provide the ENERGIRON-ZR-direct reduction tech-nology, the DR technology with inte grated CO2 absorp-tion system, jointly developed by Tenova and Danieli. The other one is HYBRIT®, an initiative for fossil-free steelmaking, established in 2016 by Hybrit Development AB, a Swedish joint venture between SSAB, LKAB and Vattenfall, with the aim to replace coking coal with hydrogen in order to obtain a fossil-free steel-making process route with virtually no carbon footprint.

In the framework of Industry 4.0, we are investigating the use of Additive Manufacturing (AM) as alternative techno-logy for the production of some defined metal parts. At METEC, we will present our vision towards the development of large-scale AM powder production able to leverage economies of scale and lowering production costs.

Last but not least, we have recently embarked on a new challenge together with ORI Martin – one of the main European integrated steel groups specialized in high-quality steel,


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with whom we have a long-standing collaboration – called Lighthouse Plant “Acciaio_4.0”. Our goal is to create a Cyber Physical Factory at ORI Martin’s steel plant in Brescia (Italy), i.e. the first model of massive appli cation of the Fourth Industrial Revolution’s techno logies.

Are you expecting new businesses to be generated at the trade fair?Pancaldi: We know by experience that it is a favourable occasion to generate first leads and even sing contracts. This is evident when we look at the quality of the visitors, as over 60 % are directly involved in investment decisions.

However, I would not want to focus only on potential clients, but also on partnerships: nowadays, innovation is not a solitary road, but a challenge that needs to be taken on with other players of the industry, active along the entire value chain. At the fairs, we hope to network with steel-makers, start-ups, academic and research centres, as well as representatives of relevant institutions.

How do you evaluate the business climate in general?Pancaldi: In 2018, worldwide steel production reached 1,808.6 million t, representing a 4,6 % increase compared to the same period of 2017. According to Worldsteel, the growth for 2019 is forecasted to be around 1–2 %: still positive, but in a lesser extent in respect with 2018. At a global level, the uncertainty about trade issues and duties,

already present in the second half of 2018, will persist in 2019, affecting steel production.On the other hand, the need to increase the quality of the final products and to comply with environmental rules and sustainability will drive new investments in some countries, above all in the Far East regions. In China, governmental actions to sustain production, as well as the conversion towards more sustainable technologies, granting new investments in mills revamping and conversion to greener solution such as Electric Arc Furnaces (EAF). In the US, the market is undergoing strong momentum due to govern-mental support to steel producers and spurring investments in adding new capacity and increase efficiency.

Together with the developments and application of the new technologies related to the reduction of CO2 emissions and to the saving of energy consumption, new investments are fore-casted in the lines for silicon steel in several regions (in par-ticular Europe, Russia and China), while in the US, we see a very active market for the heat treatment of plates. The demand for aluminium treating plants will continue this year, driven above all by the switch from the original equipment manu facturers to aluminium-based components in cars industry.

Investments in the coming years will focus on quality and technology improvements related to energy consumption, environmental impact and operating costs optimization, together with moderate investment in adding capacity above all in countries with high level of net steel imports.


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INTERVIEWGlobal Gas-Systems DUNGS®.

Global Engineering in acc. to local standards.Global manufacturing network.DUNGS best-in class production standards.

System Engineering

System Solution

Minneapolis / U.S.A.

Barcelona / E

Birmingham / GBStuttgart / D

Pune / IND

Shanghai / CN

Moskau / RUS

THERMPROCESS 2019Stand-Nr. 9D59www.dungs.com

NEWS Events

THERMPROCESS Symposium – TimetableAccompanying this year’s THERMPROCESS exhibition, the THERMPROCESS Symposium will take place from 26 to 28 June, 2019 in Hall 9 / Stand D74. Against the background of the efforts to achieve the climate targets, various lectures will be devoted to the topics of energy efficiency and emission reduction. Furthermore, the current and future challenges

of digitisation and Industry 4.0 are reflected in many contri-butions. Participation in the symposium is free of charge for THERMPROCESS trade visitors. This makes it possible to make an on-site decision at short notice in order to find out about the latest developments in the industry. All presentations will be available for download after the event.

Time Company Speaker Lecture

Chairman: Prof. Dr. Egbert Baake, Hannover

10:00–10:30 EMA Indutec GmbH Michael Bergmeir Advantages of the inductive fixture hardening

10:30–11:00 Himmelwerk GmbH Dr. Andreas Seitzer Application of induction heating solutions for e-mobility

11:00–11:30 Inductoheat Europe GmbH Alexander UlfertsInduction heat treatment processes in times of Industry 4.0 and IoT

11:30–12:00 Kanthal AB Daniel Burton The future of heating technology – It’s electric

SESSION 1 – WEDNESDAY, 26 JUNE 2019

Chairman: Dipl.-Ing. Lars Böhmer, Frankfurt

13:00–13:30 Aichelin Service GmbH Dip.-Ing. Carsten Stölting#jakob – The manufacturer- independent digital maintenance assistant for heat treatment plants

13:30–14:00 Honeywell Thermal Solutions Andreas Büscher Transform your thermal process

performance with digitization

14:00–14:30 ALD Vacuum Technologies GmbH Harald Kirsch

The essence – Convergence of digitalization and intelligent technologies as enablers for a successful Industry 4.0 or smart factory strategy

14:30–15:00 LOI Thermprocess GmbH Dr. Christian Wuppermann Advanced process modelling for smart production


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THERMPROCESS SYMPOSIUM

Events NEWS


Chairman: Prof. Dr-Ing. Eckehard Specht, Magdeburg

10:00–10:30 LOI Thermprocess GmbH Sascha BothenInnovative revamping concepts for enhanced product quality and emission reduction

10:30–11:00 Seco/Warwick S.A. Maciej Korecki PhDSingle piece nitrogen quenching instead of presshardening

11:00–11:30 ALD Vacuum Technologies GmbH Harald Kirsch

Industry 4.0 Roadmap – Methodology for the successful implementation of an Industry 4.0 strategy in a complex production environment

11:30–12:00 Institute ofTechnology (KIT)

Prof. Dr.-Ing. Dimosthenis Trimis

Energy efficient coil coating process (ECCO)

12:00–12:30 Aichelin Holding GmbH Dr. Herwig AltenaWeight reduction of automotive components by optimized head treatment processes

SESSION 2 – THURSDAY, 27 JUNE 2019

Chairman: Dipl.-Ing. David Diarra, Aachen

13.30–14.00 WS Wärmeprozess -technik GmbH Dr. Joachim G. Wünning High efficiency, low NOx

14:00–14:30 LOI Thermprocess GmbH Dr. Dominik Schröder Use of hybrid energy in industrial furnaces

14:30–15:00 Noxmat GmbH Matthias WolfLowering emissions on thermo processing equipment, yet improving on efficiency

15:00–15:30 Durag Holding AG Dr. Cornelius Wülker

Detection of fuel type and fuel quality fluctuationsby a real-time flame stability measurement

15:30–16:00 Tenova S.p.A. - Italimpianti Massimiliano Fantuzzi Tenova combustion technologies


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Chairman: Prof. Dr. Hartmut Krause, Freiberg

10:00–10:30 Otto Junker GmbH Tom Schmidt Efficient recycling of contaminated scrap

10:30–11:00 GHI Hornos Industriales, S.L. Surya Romero Smart plants for aluminium recycling

11:00–11:30 LOI Thermprocess GmbH Wolfgang Eggert/ Jingchang Sun

Modern heat treatment of silicon steel (NGO)

11:30–12:00 Schmidt + Clemens GmbH & Co. KG Dr. Shankar Venkataram

Advanced heat resistant castings as enabler torealize process benefits in thermal processes

SESSION 3 – FRIDAY, 28 JUNE 2019

FOGI Special Show with panel discussion

The Research Organisation Forschungsgemeinschaft Industrieofenbau e.V. (FOGI), founded in 1967 by mem-

ber companies of the VDMA Thermoprocess Technology Department, is active in pre-competitive joint research for the development and optimisation of thermoprocessing processes and plants. As part of the FOGI special show in Hall 10, Booth C04, nine German research institutes will present current projects and key areas of work.

The panel discussion will be held under the motto “Climate goals 2050: Hot iron – cool heads”. The partici-pants will discuss the question how thermprocess tech-nology can meet the demands of the Paris Agreement. The discussion will be moderated by Lars Böhmer, General Manager of FOGI. Part in the discussion will take:

■ Dr. Vera Finke, chairman FOGI; Rath GmbH, Meißen ■ Dr. Joachim G. Wünning, chairman department

Thermprocesstechnology at VDMA Metallurgy; WS Wärmeprozesstechnik, Renningen

■ Dr. Christian Wuppermann, LOI Thermprocess GmbH, Essen

■ Frederike Krebs, VDMA European Office, Brüssel ■ Dr. Egbert Baake, Institute of Electrotechnology,

Leibniz University, Hannover ■ Elmar Pohl, Oel-Wärme-Institut (OWI), Herzogenrath

Panel discussion will take place on Tuesday, 25. June from 15:30 to 17:00, at THERMPROCESS-Symposium-Stand, Hall 9, Booth D74. The discussion will be held in German language.

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ecoMetals and ecoMetals Trails

The ecoMetals campaign by Messe Düsseldorf is an established feature and has been a success story for

a long time now. It is no secret that sustainability, mini-mization of resource consumption and energy efficiency are current trends in the energy-intensive foundry and metal-lurgical industries. Modern technologies that minimize resource consumption and improve energy efficiency play a not inconsiderable role when industrial customers are making investments. There can be no doubt that companies which excel in these areas will also be popular destinations for visitors to GIFA, METEC, THERMPROCESS or NEWCAST.

Messe Düsseldorf responded to this trend as early as 2011 by launching a special campaign focusing on this issue, in which the leading companies in the industries spontaneously took part by presenting their technological innovations. The emphasis this year is again on environ-mentally sound operation and production in the sector, with resource and energy efficiency, climate protection and innovative processes and products as the main priorities.

About 30 exhibitors will be presen-ting their accomplishments under the heading “ecoMetals@Bright World of Metals“. Visitors can obtain a personal insight with the “eco-Metals Trails”. Tour guides will lead the visitors to the stands. Meeting point is alwayss at Entrance North (Nord)/Mall. For further information please visit: www.thermprocess-online.com/ecometals


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WWW.OTTO-JUNKER-mORE.COm

Advertisement

NEWS Events

Trends: E-Mobility, Digitization and Sustainability

E-Mobility, digitisation and sustainability are major trends that will change the markets and regulations for therm-

process technology. The market share of electric cars is picking up speed this year and companies are increasingly turning into smart factories. The main driving trend regarding regulations Is sustainability.

E-MOBILITY: BIG CHANGE IN THE AUTOMOTIVE INDUSTRYE-Mobility is changing the automotive industry. It requires new technology in all sectors including sensors, engines and all kinds of components. Experts expect the tipping point at which conventional drives will decline more strongly to occur from 2023 onwards. In four years, almost 30 % of new registrations for passenger cars could be equipped with hybrid or electric drives. New develop-ments such as iDisc from Buderus Guss is not only usable for commercial vehicles but also benefit electrical vehicles.

iDisc: significantly less brake abrasion“More than 30 % of particulate matter comes from micro-scopically small rubber and brake dust particles on the tires and brakes,” explains Gerhard Pfeifer, Managing Director at Buderus Guss GmbH. Buderus Guss, a subsidiary of Bosch since 2005, and Bosch Research developed the iDisc over many years. It is a hard metal-coated brake disc with an interlayer that robustly connects the grey cast-iron disc and the tungsten carbide coating. It has proven to be wear resistant and creates significantly less brake abrasion. Compared to conventional brake discs, iDisc causes up to 90 % less brake dust, emphasises Buderus Guss. Incidentally, heavy-duty traffic also benefits from iDisc. Pro-longed brake service intervals are economically appealing, especially for fleet operators such as haulage companies. In addition, they ensure operations continue even at higher temperatures. Another benefit is that the hard metal-coated brake discs don’t corrode. A plus that also benefits electric cars. Because electric cars primarily use the electric motor to brake, they use their brake discs significantly less often. Despite this, corrosion is not a risk, which in turn means the braking system is always ready

for operation. This year, OEMs are presenting nume-

rous electric cars. VW, Porsche, Audi and

Mercedes-Benz are showcasing new models, most of them equipped

with iDisc.

DIGITISATION: INDUSTY 4.0 IS GETTING REAL Digitisation and Industry 4.0 help the industry to be more efficient. Communication within a company and the ability to quickly exchange information with customers and sup-pliers are important requirements for using knowledge in the spirit of Industry 4.0.

Autonomous Engineering by MagmaAutonomous Engineering for example enables users to consider opposing goals regarding economic feasibility and quality. It already supports casting design, robust process design and optimised casting parts evaluation before the first cast. Using this new method, various parameters can be examined prior to the start of production. Instead of calculating a variant, the system calculates experimental space. This allows users to evaluate more possible calcu-lations than ever before and thus enables them to pursue different quality and cost objectives at the same time. This generates extensive knowledge for designing and controlling the entire casting process as well as concrete, practical measures, whilst taking design and process requirements into account,” explains Magma, the company which developed the new system. Results produced by the current version Magmasoft 5.4 range from evaluating and optimising work flows for casting defects, residual stress and warpage to structural composition and heat treatment.

SUSTAINABILITY: FACING THE CLIMATE CHANGE Foundries are one of the best examples of resource effi-ciency and sustainability. Because castings implement the recycling concept almost completely. Once their life cycle is over, castings are recycled, i.e. they are melted down to manufacture a new casting. Old and new scrap metal is used to produce castings too. Iron and steel foundries buy about 3.5 million different scrap materials year in, year out. About 95 % of the sand required to make moulds is recycled as well. Modern processing systems make this possible.

Additive manufacturing to save energy and resourceSimulation and, to an increasing extent, 3D printing are making it possible not merely to produce highly complex parts but also to replace the energy-/resource-intensive and time-consuming trial and error method. The Leipzig team from GF Casting Solutions came to this conclusion, too. Series production of sand cores by 3D printing started here in the summer of 2018. The cold-curing phenolic 3D printer has several advantages: considerable time and money is saved in the production of prototypes and spare


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parts, process reliability is increased by the elimination of core assembly and the design potential is unlimited. There are many different application areas for the castings, which weigh between 100 and 1,000 kg, such as lorries, construction equipment, agriculture and forestry manage-ment, solar farms and wind turbines, rolling stock, machine manufacturing in general and hydraulics.

Products with greater impactCesare Troglio, Technology and Innovation Division Manager at the German Foundry Association (BDG) summarises: “Such technologies can help to save a great deal of time and energy when tooling is being built, particularly where prototypes and short series are concerned”. The progress that has been made with organic bonding agents and the use of inorganic bonding agents of the kind developed by, for example, foundry supplier ASK Chemicals also improves environmental performance.:

The company has succeeded in developing the first unmarked phenolic resin in the world for the cold box process in iron casting. A hazardous product is not therefore needed in this process. Furthermore, it is possible to reduce bonding agent and catalyst volumes in many cases because the system is particularly high reactive. Inorganic bonding systems are becoming increasingly important in aluminium casting. ASK Chemicals is also noticing greater awareness of sustainable products. According to Müller this is driven by the fact that the general conditions in Europe particularly have become more demanding due to the implementation of relevant regulations.


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Thermprocess,

Düsseldorf

June 25 – 29, 2019

Please visit us:

Hall 9, Booth E40

VACUUM SOLUTIONS FOR METALLURGY

Are you looking for a perfect vacuum solution? Please contact us:Pfei�er Vacuum GmbH · Headquarters/Germany T +49 6441 802-0 · www.pfei�er-vacuum.com

Extended lifetime with UnoLine Plus rotary vane pumpsDo you want to improve the lifetime of your vacuum system in harsh processes? The reliable and rugged process pump UnoLine Plus can handle harsh conditions such as water vapor and even binder materials present in applications like Hot Isostatic Pressing.

Ensure leak tightness with ASM leak detectorsEnsure process stability and reliability of your vacuum furnace with our leak detectors. We can provide mobile or multipurpose leak detectors tailored to your needs.

Reduce your cost of ownership with HiLobeAchieve savings in cost of ownership for your vacuum system of up to 50 %1) with our new generation of Roots pumps HiLobe. Our new drive concept ensures low electricity consumption, while the condition monitoring option makes custom maintenance intervals possible.

1) The actual saving depends on the application as well as on the particular models.

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FOCUS ON Edition 27

How important are the trade fairs GIFA and THERM-PROCESS for your company?Rische: The exhibitions in Düsseldorf continue on a high level and are up to date with the world’s trends and technologies. Therefore, we invited customers from all over the world, who are planning to attend the event to discuss the newest developments with us. Also from local markets we received many inquiries for participation at these exhibitions.

What products will you present in Düsseldorf?Rische: The central part of our booth is a 6t-induction melting furnace type FS60, one of the main products in our portfolio. Furthermore, we exhibit a heating furnace to display the combination of IGBT converter technology with modern control systems in connection with a highly advanced predictive numerical calculation model. In the field of new casting technologies, we are focused on the low-pressure casting process and the associated benefits for our customers.

In addition to our traditional products from our product line, our booth is focused on the presentation of our develop-mental results from the past year in the field of digitalization products. The central point is the symbiosis of the existing high-performance hardware products with possibilities of the developments from big data collection, evaluation and improvements in combination with artificial intelligence.

What trends and technologies are shaping the industry?Rische: The obvious trends are productivity, security and environment. These three trends complement each other for the benefit of our customers. In addition to the latest safety technologies and the energy efficient systems we are focusing on digitalization.

Cost pressures caused by trends in globalization lead to higher demand of quality improvements and increases in productivity. Since improvements in standard equipment developments are limited, a significant potential lies in using the possibilities of digital products in connection with hybrid services. This is the future potential for differentiation in productivity and quality.

Are you expecting new businesses to be generated at the trade fair?Rische: We have a very close relationship with our custo mers and contract conclusions at the fair have of course a history. However, in the past it has been shown that participation in the trade fair brings us together with new potential partners and gives us the opportunity to present ABP as a technology leader.

With our development partners we have demonstrated that our new digital products provide the desired results and validate our strategic focus. Of course, this still young digital technology with the resulting opportunities for our industrial applications offers great potential for new business.

How do you evaluate the business climate in general?Rische: Due to the current political environment a state-ment is not easy. From our point of view the general business climate is, as often in the past, inconsistent. Many of our customers have a very high level of utilization. This shows a high business level in aftermarket. Compared to last year also the project volume has been improved. But our customers also postpone decisions as far as possible.

A faster action of the politics would be quite beneficial. However, for the next years we expect a stable or growing business.

“The trade fair brings us together with new potential partners”Dr. Marco Rische, Chief Technology Officer of ABP Induction Systems GmbH Here you can find ABP: Hall 10, Booth B42


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LOI Thermprocess presents wide range of industrial furnace plants

Tenova LOI Thermprocess will exhibit their wide range of industrial furnace plants at this year’s THERMPROCESS

and METEC fair. LOI’s role has lately changed from a pure furnace plant supplier to a technological partner. Their heat treatment plants for steel and aluminium products distinguish them selves not only by the plant features, but also by ensuring the mechanical properties of the custo-mers‘ products.

In the field of aluminium melting, LOI is specialized in scrap melting with minor melting loss and is worldwide very successful with the third generation of twin-chamber melting furnaces. The latest developments for process guidance contribute to an increased metal yield together with lower emissions.

Regarding the aluminium heat treatment plants, LOI focuses on plant flexibility for various automotive com-ponents and highest cooling rates that are also applicable to special alloys. To ensure the proper cooling rate for each material, the plant design follows the analysis of decisive criteria.

In the steel area, LOI has extended the product range for steel heat treatment to both extremely thick and thin plates.

The automatic creation of recipes is indispensable for the heat treatment of various types of railway wheels. Highly complex quenching facilities ensure a uniform fine- pearlitic structure down to a depth of 45 mm. In the heating

sector, LOI offers numerous plants for forges and roll-ing mills. An adjusted process guidance allows the low- decarburization heat treatment of carbonaceous materials.

The product range of LOI includes plants for both non-grain oriented (NGO) and grain-oriented (GO) electrical sheets. In the area of continuous heat treatment, the furnace plants comprise annealing-pickling lines (APLs for NGO and GO), decarburization lines (DCLs for GO), final coating lines (FCLs for GO), annealing and coating lines (ACLs for NGO) as well as high-temperature batch annealing furnaces for annealing temperatures > 1,250 °C (MBAF for GO).

For the heat treatment of tubes, rods and wire, LOI supplies tailor-made solutions for the continuous heat treat-ment in roller hearth furnaces as well as for the batch-wise heat treatment in bell-type annealing furnace plants. Protec-tive gas atmospheres such as 100 % N2 to 100 % H2 as well as process-controlled reaction gases (e. g. endogas) can be used.

In the area of heat treatment of steel strips, the fully automatic crane operation in LOI‘s unique HPH bell-type annealing plants ensure high production output with lowest consumptions.

LOI Thermprocess GmbH www.loi.tenova.com Hall 4 / Booth A21

Hall 9 / Booth B53


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PRODUCT PREVIEW – Industrial Plants & Furnaces

NEWS Events

Cooling technology to offer flexible control

If a steelmaker is focused on high strength steel develop-ment, then rapid cooling within a vertical furnace would

be a crucial process in a strip processing line. Fives’ new development is the Wet FlashCooling technology for Gen3 AHSS; The company will make a presentation on this subject during the ESTAD conference.

The Wet FlashCooling technology has been developed to offer full flexible control of the strip cooling cycle, including control of final strip temperatures, accurate modu-lation of cooling rates and strip crosswise temperature homogeneity control.

This technology has been successfully operating in trip processing lines for the

last 10 years and is under implementation on a new auto-motive strip processing line in the US.

At Fives, the Steel business line provides steelmakers with complete solutions: process exper-tise and breakthrough technologies for the carbon, stainless and silicon steel sectors to optimize performance (costs and product quality) and meet the new needs and applications of the steel market, in particular high value-added steel grades.

Fives SAS steel.fivesgroup.com Hall 9 / Booth E58

Otto Junker: Focus on energy efficiency and automation

Under the theme of more, Otto Junker and Induga will present high-quality solutions at Booth H41 in Hall

10 to give users added value at multiple levels, especially in the spheres of induction, convection and automation.

Otto Junker will inform visitors about individual solu-tions in the product range of induction-type melting and pouring systems, which the Group tailors specifically to the user’s processes.

Exemplified on an energy-saving medium-frequency coreless induction furnace, Otto Junker will showcase its Optical Coil Protection (OCP) system delivering direct in-crucible temperature measurements for more operating safety and reliability. In addition, operators can learn more about process control as achieved with Junker’s furnace control system JOKS or the MFT i4.0 mobile application. Induga is set to advise visitors on customer-specific solu-tions while also presenting the Puma Pro pouring system, which delivers more in terms of, e. g., pouring precision,

productivity and process stability. Under the Thermcon brand, Otto Junker offers gas-fired melting and pouring furnaces for aluminium. On the basis of a plant model, users can find out about the advantages of a productive system with pyrolysis technology for recycling contami-nated aluminium scrap.

In the segment of convection or induction-heated thermo processing equipment, Otto Junker offers a com-prehensive portfolio enabling operators to obtain a furnace solution optimized to match the given application case and space availability.

In addition, the Group will inform visitors about the productivity and flexibility of its energy-saving systems and on how custom heating and quenching processes can increase the quality of aluminium or copper products. With offline versions of their process models, the Group’s furnace specialists empower users to develop suitable recipes and charge sequences.

Customer service personnel will likewise be on hand at the fair. This staff will be glad to advise visitors on available maintenance and upgrading options for existing equipment. For the Live Forum, the furnace specialists have assembled a compelling program of presentations and lectures. Held in English, these oral abstracts will familiarize visitors with the advantages of the relevant products and services.

Otto Junker GmbH www.otto-junker.com/en Hall 10 / Booth H41


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Industrial Plants & Furnaces – PRODUCT PREVIEW

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Welcome to JUMO. www.jumo.net

Portable measuring system according to AMS2750 and CQI-9 – JUMO thermoCORDo you value efficiency, accuracy, and durability? Do you believe that quality is the product ofexperience, innovation, and practical relevance? Then you have found your perfect partner:

Implementation of SAT and TUS tests

Creating and managing test reports

Tamper-proof recording using TÜV approved JUMO PCC and PCA software

Mobile version in high-quality and robust design

Various JUMO service packages available

Checking reliably.

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Example setup:TUS test with JUMO thermoCOR

Visit us in

Hall 10, Booth 10G60

Events NEWS

Heat treatment and diffusion coating furnaces

Electron Thermal Processing Equipment offers heat treatment and diffusion coating equipment. New heat

treatment and coating process technologies have been developed, validated and tested including the latest tech-nologies in coating for industrial gas turbines.

Electron’s large-scale heat treatment and/or coating furnaces offer high-capacity and cost-effective solutions for heat treatment, cleaning and (internal) coating of F-class and other hot section gas turbine components.

The company provides both equipment and process know-how as solution to the gas turbine component repair industry. The state-of-the-art furnace system can be used to perform either one or a combination of processes, such as Vapour Phase Aluminizing (VPA), Vapour Phase Chromizing (VPC), Chemical Vapour Deposition (CVD), Hydrogen

Fluoride Ion Cleaning (FIC) and heat treatment under con-trolled atmosphere.

The coating furnace has a modular design and can be delivered in a single or multiple reactor (retort) configu-ration. The system has a variety of features, like a process chamber with OD 1,200 mm for large batch capacity, fast heating and cooling rates, high temperature uniformity, homogeneous gas distribution, controlled diffusion rate with mass flow-controlled gas system and it is suitable for external and internal coating.

Electron Thermal Processing Equipment BVwww.glaesum.nl/en/electron

Hall 9 / Booth D60


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Welcome to JUMO. www.jumo.net

Portable measuring system according to AMS2750 and CQI-9 – JUMO thermoCORDo you value efficiency, accuracy, and durability? Do you believe that quality is the product ofexperience, innovation, and practical relevance? Then you have found your perfect partner:

Implementation of SAT and TUS tests

Creating and managing test reports

Tamper-proof recording using TÜV approved JUMO PCC and PCA software

Mobile version in high-quality and robust design

Various JUMO service packages available

Checking reliably.00

052

Example setup:TUS test with JUMO thermoCOR

Visit us in

Hall 10, Booth 10G60

Advertisement

NEWS Events

Turnkey plants and furnaces for aluminium recycling

Recycall, GHI’s fully automated aluminium recycling plants are designed to obtain the highest metal yield

for any kind of scrap.These tailor-made, flexible, eco-friendly and scalable

plants, include cutting-edge technology and are conceived from the design stage to be integrated into Industry 4.0 enabling process control, optimization and continu-ous improvement. Furthermore, a corrective, predictive and preventive maintenance is achieved thanks to the Beyond 4.0 technology. Recycall plants include, but are not limited to, the following equipment:

■ Tilting rotary furnaces to recover aluminium from low-grade scrap, with an exclusive double door sys-tem that allows loading without interrupting the melting process, thus increasing the energy effi-ciency. GHI references include a 65-t capacity rotary furnace.

■ As auxiliary equipment skimming machines, scrap loaders and fume collection systems can be provided

■ Cooler systems to improve the recovery rate by rapidly cooling the salt slag produced by the tilting rotary furnace

■ Vortex melting furnaces, specially designed to increase the metal yield when melting fine-grade scrap, such as chips or UBC

■ Decoating and drying system to remove the organic and inorganic contaminants prior to introducing the scrap into the melting furnace and reduce the metal losses

■ Rever beratory holding furnaces, to hold and alloy the molten aluminium, and with GHI’s exclusive porous plugs technology to improve the quality of the alu-minium by homogenizing the composition and the temperature of the metal

■ They may include a weighing system, molten alumini-um bath level control, among other features;

■ Ingot casting machines, to produce ingots in a fast and continuous way, guaranteeing that all ingots are uniform in quality, weight and dimensions

■ Transport ladles, for shipments by road of molten aluminium.

GHI designs and supplies turnkey plants for recycling and recovering aluminium from dross, jointly engineered by all the stakeholders in the process with the aim of offering the solution that best meets the customer’s current and future needs and including all the components required to ensure the efficient operation of the aluminium recycling plants.

GHI Smart Furnaces www.ghihornos.com Hall 10 / Booth F39

SMS group makes digitalization a live experience

At SMS group’s METEC booth, visitors will get first-hand information about the entire technology and service

portfolio offered by SMS group. Additionally, at ESTAD 2019 (European Metallurgical Steel Technology and Application Days), SMS group experts will be presenting new develop-ments accomplished during the last few years in more than 60 technical papers. The ESTAD 2019 conference will be held at the Congress Centrum Düsseldorf (CCD) from 24 to 28 June 2019.

SMS group is a trailblazer in digitalization for plant and equipment used in steel and NF-metals production and processing. At METEC, the company is going to demonstrate by way of examples of projects implemented at its customers how networked systems, self-learning process models, smart assistance systems, artificial intelligence and virtual reality have revolutionized engineering, production and maintenance in steelworks and rolling mills and how its customers benefit from a stronger competitive standing as a result.

With its holistic approach to process control along all stages of the supply chain – as in the learning steel mill –

SMS group builds not only highly efficient new production facilities, but it also upgrades existing ones to a state that compares with that of new plants.

Additionally, SMS group is the spearhead of Additive Manu facturing in the industry. The company already uses additively manufactured components in its plants and has been promoting the development of highly specia-lized metal powders. The powder atomization plant in Mönchengladbach, Germany, is not only used for the pro-duction of high-purity metal powders for AM applications, but also develops new design and manufacturing methods there.

SMS group will present its innovations under the umbrella topic “New Horizon”. In more than 150 years the company has accumulated a wealth of expertise based on which it has started to address urgent and future-oriented topics in a concerted approach: How will we be using raw materials in the future, or energy and our environment? How do we go about topics like mobility, urbanization and the communications sector?


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Burkhard Dahmen, Chairman of the Managing Board of SMS group GmbH, says: “Metals are essential for our future: high mobility, urban life or intensive communication would be impossible without metals. Therefore, we develop technologies for the complete life cycle of metals. We offer technologies that extract and process metals in an econo-mically efficient and, at the same time, eco-friendly way, and allow them to be recycled virtually endlessly back into the raw material cycle. With our “New Horizon” offensive, SMS group is gearing up for future markets.”

Against the backdrop of constantly decreasing resources of metals that are crucial for the application of new technol-ogies – such as nickel, cobalt, aluminium oxide, titanium, vanadium, lithium or rare earths – SMS group has developed new, profitable processes for the extraction of metals from secondary sources and sources that could only be exploited with limited efficiency in the past. Besides that, the company designs resource-saving, integrated plant solutions for pri-mary and secondary process routes in non-ferrous metals production within the joint venture PolyMet Solutions. The Luxembourg SMS group company Paul Wurth develops new CO2-free steelmaking techniques that make for a significantly smaller CO2 footprint of the steel industry. Cooperating with Sunfire, a company based in Dresden, Germany, Paul Wurth is taking a direct reduction process to market maturity, in which the fossil element carbon is substituted with hydro-gen, and from which no climate-damaging CO2 arises, only water vapor. In this context, Paul Wurth also engages in the research of systems for the production of green hydrogen, which is produced exclusively with renewable energy. In a cooperation with UrbanGold GmbH from Austria, SMS group has developed an economically efficient process able to recover and feed back into the raw material cycle high-grade, valuable materials previously considered as lost materials

from electric and electronic scrap – e. g. gold, silver, platinum, nickel or copper. A first plant for the recycling of electronic circuit boards will be started up shortly.

Burkhard Dahmen: “The last few years have seen continual talk of digitalization, Industry 4.0 and Additive Manufacturing at the steel producers and processors as well as at their suppliers. We already feel the heavy impact of new technologies and new production methods in our world of work. We will see this impact cause even more change at an ever-faster pace in the future. Since last METEC we have seen many changes taking place in many different areas. Against this background, we look forward to speak with our customers about the challen ges posed by these megatrends – and to propose possible solutions. In this way, we can help our customers to stay competitive in a globalized market environment.”

SMS group GmbH www.sms-group.com Hall 5 / Booth E22

Open Area FG05


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GAS PRESSURE REGULATORS

SAFETY SHUT OFF VALVES SAFETY RELIEF VALVES PILOT OPERATEDGAS PRESSURE REGULATORS

CELLULAR GAS FILTER

MEDENUS REGULATORS

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MEDENUSGas-Druckregeltechnik GmbHSaßmicker Hammer 40 · D-57462 Olpe

Tel. +49 (0)2761 82788-0 Fax +49 (0)2761 [email protected]

We look forward to meet you. Hall 9 / A34

Advertisement

FOCUS ON Edition 27

“This fair enables open discussion with worldwide steel professionals”Philippe Cruiziat, Executive Vice President, Sales & Marketing at Fives’ Steel Here you can find Fives: Hall 9, Booth E58

Can you please outline Fives’ activities for the steel industry?Cruiziat: Fives is a global industrial engineering company that operates in many market sectors, one of which is the steel industry. We have been supplying engineering solu-tions, technologies and equipment to steelmakers since 1867. Today, we offer both technical and strategic solutions to support steelmakers via our expertise from business strategy consulting services to high-performance techno-logies for carbon, stainless and silicon steel production.

How do you evaluate the business climate?Cruiziat: Overall, performance efficiency, reducing energy consumption and new grade developements for new markets are the focus points for all steelmakers. In our main market, China is relocating production facilities and targeting environmental sustainability. At the same time in the United States, the domestic steelmakers say there has never been a better time to make steel following increased tariffs introduction, which have been a real boost to the domestic industry.

Over the last two years, Fives has diversified its geo-graphical coverage, having concluded important contracts in the United States, Europe and Russia.

In the US, for example, we have been entrusted with the design and supply of a new continuous galva-

nizing line (CGL No. 3) for the Steel Dynamics plant in Columbus, Mississippi (400,000 t/a) and on the same site, Fives was contracted to upgrade a continuous galvanizing line (CGL No. 2) to increase production capacity. Also in the US, Fives has signed its first contract for a ceramic coating line.

What products will you present at the trade fair in Düsseldorf?

Cruiziat: Most often we can see that the major investments in the world are focused on energy

efficiency, environmental protection and digi-talization. Since its foundation in 1812, Fives has been at the forefront of innovations

and breakthrough technologies, some of

which were developed together with leading steelmakers. These technologies are the core of our businesses and they will be presented during the trade fair. I will mention a few:

We will present the Smartline, a true automatic pilot for galvanizing lines which incorporates predictive models for all the key process steps as well as for the metallurgical behaviour of the products. We have been developing this Smartline solution together with Marcegaglia Cabron Steel for their four galvanizing lines in Ravenna, Italy. This autopilot also takes into account a number of process and quality rules which simultaneously apply to all the key process steps of the galvanizing line – i.e. the annealing cycle, the zinc coating and air-knife wiping, and the skin pass rolling – to establish the optimum setpoints for each of these critical process functions while optimizing the overall output of the line. The result is an optimal real-time control of the line that delivers the best possible overall product quality and productivity.

Keeping digital solutions in mind, we will also be high-lighting our real time quality management tool – Eyeron. It is a real-time automatic product qualification system, which provides full traceability of all process steps and of all quality events from the melt shop down to the cold rolling and processing lines while delivering product qualification and certification within seconds after the product comes off the line. It has demonstrated savings in terms of yield improvement amounting to several million of euros per year for fully integrated steelmaking sites. In 2018, it was installed in a steel shop, a hot rolling mill and a plate rolling shop of Severstal, a leading Russian steelmaker.

For the thermal process, our Stein Digiflex furnace was awarded Engineered Sustainability brand for its eco- design features, for being the best-in-class product in terms of environmental performance. Fives was one of the first designers of capital goods to formalize its eco-design program – Engineered Sustainability – which is known to meet strict and transparent specifications. Technological highlights include the ability to reduce NOx emission to less than 50 ppm. The furnace is able to utilize any fuel – natural or coke oven or mixed gas depending on the client’s available utility conditions. It fully complies with the latest European standards and particularly EN 746-2.


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Our DMS 20Hi EcoMill, a cold rolling mill for stainless steel, is able to roll strip down to 0.04 mm (40 microns) on the full width of 1,250 mm. This mill was installed at Shanghai Stal Precision Stainless Steel, China last year and is producing ultra-thin stainless steels for high-end applications.

What was the latest Fives innovation for the steel industry?Cruiziat: If a steelmaker is focused on high strength steel development, then rapid cooling within a vertical furnace would be a crucial process in a strip processing line. Our new development is Wet FlashCooling technology for Gen3 AHSS; we will be making a presentation on this subject during the ESTAD conference.

The Wet FlashCooling technology has been developed to offer full flexible control of the strip cooling cycle, including control of final strip temperatures, accurate modulation of cooling rates and strip crosswise temperature homo-geneity control.

This technology has been successfully operating in trip processing lines for the last 10 years and is under

implementation on a new automotive strip processing line in the US.

How important are the trade fairs GIFA/METEC and THERMPROCESS for your company?Cruiziat: Fives is a regular attendee of GMTN. We will present our process innovations, technologies and digital solutions for steelmakers, as well as low-emission combustion equipment for different industries.

During the 4th European Steel Technology and Appli ca-tion Days (ESTAD), we will make several technical presen-tations on Wet FlashCooling technology for Gen3 AHSS; combustion solutions 4.0 for a better environmental footprint; high-flux induction heating solutions as an alternative to conventional steel strip heating processes; advanced cold rolling improvements for silicon and stain-less steel, and the 3rd generation carbon steel mechanical equipment for processing lines.

This fair is also a good opportunity for open discussion with worldwide steel professionals – and a chance to reconnect with our steel family for a whole week.


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Order now and save the knowledge!

PLANTS AND FURNACES, PROCESS ENGINEERING

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This book describes the following aspects:

• discussion of melting technology

• detailed concentration on the metallurgical process- engineering of induction facilities for melting, temperature maintenance and casting

VULKAN VERLAG. FOR PEOPLE WHO WANT TO KNOW MORE.

Erwin Dötsch3rd edition 2019Article number: 31099Also available in eBook format.Price: € 80,-

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NEW EDITION OFSTANDARD WORK

NEWS Events

Tenova: Reducing energy consumption and increasing efficiency

The Italy-based company Tenova is a part of the Techint Group, a worldwide partner for innovative, reliable and

sustainable solutions in the metals and mining industries. Within the Metals Division, Tenova offers a fully integrated range of high-quality products, technologies and services for the steel making route, from iron and ferroalloy ores and scrap up to secondary metallurgy and liquid steel.

Sustainability, innovation, reliability and safety are Tenova’s commitments, and the company’s technological solution always drive to reduce energy consumption and increase the overall facility efficiency. The improvements in our product portfolios and the fostered connection with our clients are developed through digital technologies, such as predictive maintenance, remote assistance and artificial intelligence. Moreover, Tenova is now taking a step forward towards the development of new integrated business models by applying the principles of Industry 4.0 and Circular Economy.

Example of these applications in reheating and heat-treating is the Tenova Self Regenerative Burner (TRGS), the smart burner that includes the optimization of the heat process through the interaction with digital application.

In the field of cold rolling, Pomini Digital Texturing (PDT) is Tenova’s new disruptive technology solution for the roll texturing market, where it is of utmost importance to achieve the correct surface quality on the metal sheet and to grant the highest performance in terms of paintability and formability.

With reference to sustainability, Tenova is working in the direction of decarbonization of steel production, replacing

carbon partially or totally with hydrogen as reducing agent of the Direct Reduction (DR) process. The company has already two ongoing pilot projects implementing this technology in Europe. One is Salcos (SAlzgitter Low CO2 Steelmaking), a revolutionary concept for a significantly CO2-reduced steel production with the DR technology (jointly developed by Tenova and Danieli) with integrated CO2 absorption system. The other one is Hybrit, an initiative for fossil-free steelmaking that was established in 2016 by Hybrit Development AB, a Swedish joint venture between SSAB, LKAB and Vattenfall, with the aim to replace coking coal with hydrogen in order to obtain a fossil-free steel making process route with virtually no carbon footprint.

In the framework of Industry 4.0, Tenova is investigating the use of Additive Manufacturing (AM) as alternative techno-logy for the production of some defined metal parts.

Another important project for Tenova is its Lighthouse Plant “Acciaio_4.0”, developed in partnership with ORI Martin (one of the main European integrated steel groups specialized in high-quality steel). The goal is to create a cyber physical factory at ORI Martin’s steel plant in Brescia (Italy), i.e. the first model of massive application of the Fourth Industrial Revolution’s most innovative technologies.

Tenova S.p.A. www.tenova.com Hall 4 / Booth A21

High vacuum metallic furnaces

Thermolab has been producing furnaces for the past four decades with customers spread across the five conti-

nents. The company is specialized in manufacturing a wide range of customized solutions for various

applications both in the industrial, laboratorial and R&D fields.

The high vacuum metallic furnaces can work at up to 2,400 °C under controlled atmosphere (vacuum, inert or redu cing). With an all-metal construc-tion consisting of heating

element and radiation shields built in tungsten and

molybdenum, high vacuum levels can be achieved for a maximum purity atmosphere.

Front, top or bottom loading designs can be used depending on the type and size of the load. Using the best available vacuum, power and temperature control technologies, dedicated control solutions can be developed to fit customer’s requirements. Additional equipment such as automatic gas control or partial pressure control can be included.

Termolab – Fornos Eléctricos, Lda www.termolab.pt Hall 9 / Booth C17


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Rotary hearth furnace with new heating technology

Schwartz GmbH has developed a rotary hearth furnace embodying an all-new heating technology for hea-

ting aluminium parts for hot forming, as well as for other applications such as T6 heat treatment. With this integrally designed rotary hearth furnace, schwartz is offering its customers multiple advantages at once over previously available furnace solutions.

The items placed in the furnace are heated uniformly, efficiently and continually across all annealing positions. This is achieved thanks to the forced air circulation system which relies on the use of a semi-axial fan to provide a convective heat transfer to the load. Flow management and heating system are designed to ensure that each annealing position receives the same amount of hot air; moreover, the full hot airflow is passed over the parts.

As the nozzles form an integral part of the product sup-ports rotating about the vertical axis, all products are heated continuously from the time they are loaded into the furnace until they exit from it. As a result, each part is subject to the same convective heating conditions – i.e. the same heat treatment, including the same heating (and, if necessary, soaking) time – irrespective of its tier and annealing position. This is highly important, apart from ensuring part quality, especially for the purposes of meeting CQI-9 requirements.

The heat is supplied on the intake side of the ceiling- mounted semi-axial fan. Accordingly, the hot air gets

thoroughly mixed between the fan exit and the nozzles, which are connected in parallel in terms of flow, and a homogeneous nozzle outlet temperature is achieved.

Another advantage of this newly developed schwartz furnace is that the nozzle arrangement for each anneal-ing position can be individually adapted to the shape of the part to be heated. Thus, the furnace can be confi-gured optimally for heat-treating rotationally symmetri-cal parts, such as wheels, or items such as, e. g. engine blocks, transmission housings, or the like.

Furthermore, the furnace distinguishes itself by a straightforward and hence, cost-efficient design. Its specific structure makes it exceedingly main tenance-friendly for the user.

Walk-in access to the furnace interior for maintenance and servicing, e. g. cleaning, is possible via the furnace doors and maintenance hatches.

The first furnace built to this design was recently com-missioned and is fulfilling the customer’s expectations. An application for protection of industrial property rights has likewise been filed by now.

schwartz GmbH www.schwartz-wba.com Hall 9 / Booth F42


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NEWS Events

SyncroTherm plants with additional control features

Six years ago, “One-Piece-Flow“ (OPF) for case harde-ning processes, a feature of the first generation Syn-

croTherm plants, was introduced into the gear industry for the first time. The advantages of this technology, which is based on low-pressure carburizing and high-pressure gas quench, set the path for the direct integration into the production line, thus closing the gap between soft machining and hard machining in the gear production

chain. These advantages include high quality parts, short process times, less part distortion as well as high environ-mental compatibility.

In the meantime, further fields of application for the SyncroTherm technology were explored, offering great advantages to the users which include, for example, the expansion to other processes such as tool hardening, annealing, brazing and sintering. In addition to the OPF application, i.e. sequential case hardening of gear parts in the mechanical machining cycle, another possible use has become established regarding flexible heat treatment of small batches or lots, i.e. the so-called “Small Batch Production” (SBP). The priority lies not in the rigid produc-tion cycle but in the timely, individually customized heat treatment of small lots containing various parts in one heat treatment plant.

Meanwhile, the industry has gained substantial produc-tion experience for both applications of the SyncroTherm technology. More than 30 systems are operational, from a manually operated single plant to a complex, highly auto-mated plant system, including automated charging of the parts on a charge carrier.

Based on the proven first-generation plant technology, the new SyncroTherm 2.0 now offers additional control features in order to meet all the requirements of a modern Internet of Things (IoT) setting. These include standardized

Spares parts and welding fixtures

Between the foundation of La Résistance RD in 1947 and the foundation of the RD Group in 2013, more

than 70 years of experience have allowed RD Technologies to become a performing and innovating company in the market of thermal treatment furnaces.

In 2007, RD Technologies was founded and in 2013 the company C.A.R was taken over which gave complemen-tary know-how and responsiveness in production while encouraging the competitive capacity.

Since July 2016, RD Technologies (CAR) has joined the com-pany group Galilé. Galilé is an independent industrial group, founded by Eric Michoux, who supports the French production.

RD Technologies designs, produces, repairs and installs welded parts from refractory alloys for heat treatment fur-naces operated between 600 and 1,200 °C under diffe-rent atmosphere types, including the manufacturing of all types of parts, the improvement of existing parts and the partial or total reparation of parts. Following parts are designed, manufactured and repaired: Muffles, movable

furnace floors and rails, bell type furnaces, pots and plugs, furnace retorts, radiant tubes, turbines and engines, chains, supports and grids, conveyor belts, conveyors and eleva-tors. Design and digital simulation softwares are used in order to create realistic plans and renderings, especially for complex assembling.

The company works with all furnace brands and types of treatment as well as in all business sectors. Present in France and Europe, their customers are industrial busi-nesses companies who are processing integrate one or several lines of thermal treatment (example: automobile and engineering industry, aeronautics, armaments and power industry, aluminium production, foundries…). 65 % of the sales are for export with a network of specialized agents in Europe.

RD Technologies SAS www.rd-technologies.fr Hall 9 / Booth C51


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Heat Treatment – PRODUCT PREVIEW

Events NEWS

Oil quenching furnaces with low-pressure carburizing

Historically, the carburizing process was per-formed under atmospheric pressure, mostly

in sealed-quench or pusher furnaces. This traditi-onal approach reaches limits linked to the varia-tions of the atmosphere parameters and furnace construction, such as pressure, gas concentration and maximum furnace temperature.

Vacuum carburizing process is offering an efficient way to reduce the energy and fluid consumption. Overall, vacuum heat treatment in a modular installation helps improving ener-gy and environmental performances. The risks of fire and explosion are minimized thanks to the vacuum concept, which allows to control

the process inside a leak-tight chamber – no flames heat treatment, and direct integration in the machining line thanks to the cold wall technology.

Furnaces from the ICBP Duo TH range pres-ent several advantages. These installations can be easily integrated and set up in workshops thanks to their pitless design, up to the 966 size. Indeed, no civil engineering is needed. Also, to face an increasing demand, ECM Technologies has launched the size 1299 for bigger loads or larger volumes. All these furnaces can be easily integrated in an existing sealed quench furnace line in replacement of the atmosphere carburiz-ing technology.

ICBP Duo oil quenching furnaces used with the low-pressure carburizing technology allow reducing up to 50 % of cycle time in comparison to conventional furnaces. The treatment costs are reduced significantly.

ECM Technologieswww.ecm-furnaces.com

Hall 9 / Booth D71

interfaces for the simple integration of external plant components into the SyncroTherm 2.0 furnace system and IoT-compatible interfaces (XML) for data transmission to superior custom-er-ERP-systems.

The new plant generation offers even higher process flexibility through optional process rout-ings within and outside of the SyncroTherm 2.0 plant. Improved part and process documentation and continuous tracking of the parts during the entire production process by means of process integrated laser coding of the parts will become possible.

The web-based visualization will allow view-ing plant and charge data on any mobile device. Extensive logistic planning tools enable to opti-mize resource planning for the entire heat treat-ment process. Easy handling through plain text alarms and notifications including the display of additional information will increase the ease of operation.

An efficient automation and digitalization based on TIA portal as well as compliance to important quality standards in the automo-tive and aerospace industry, e.g. CQI-9 and NADCAP complete the advantages of the new system.

A tried-and-tested plant system was deve-loped further with the SyncroTherm 2.0, meet-ing all the demands of Industry of Things. Target markets include, among others, the automotive industry and their suppliers, especially parts for electromobility in the OPF. The SyncroTherm technology is also used successfully in the aviation industry. The use of flexible “Small Batch Production“ (SBP) broadens the application range for captive heat treaters and commercial heat treaters.

ALD Vacuum Technologies GmbHwww.ald-vt.com

Hall 9 / Booth F23


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PRODUCT PREVIEW – Heat Treatment

Accurate• Up to 20 thermocouples • For CQI-9 and AMS2750E• 2-way Telemetry• Bluetooth with Android App• 3.8 million data points• Calibration data embedded• Down to 0.2 sec. sampling over 20 channel without any loss of accuracy.

Temperature Profi ling + Surveying

PhoenixTM GmbH32549 Bad OeynhausenTel.: +49 5731 30028 0

www.phoenixtm.de [email protected]

Accurate!

Easy!• No trailing leads• Minimum preparation • Up to 1350°C• Systems for oil-, gas- or water quench available

• Comprehensive reports for AMS2750E and CQI-9

Thermprocess Show

Düsseldorf, 25-29 June

Hall 9 Booth C59

Adv

ertis

emen

t



Thermprocess

Düsseldorf, 25-29 Juni

Halle 9 Stand C59

Umfassend!Messen Sie Atmosphären-, Ober-fl ächen- oder Kerntemperaturen an bis zu 20 Punkten. Natürlich kalibriert (auf Wunsch DKD)!

TUS Messung für

AMS2750E und CQI-9

Mit Auswertung gemäß AMS2750E und CQI-9

Die TUS Lösung für Kammer, Vakuum und kontinuierliche Öfen!

Universell!

Einfach!Keine Schleppkabel, minimaler Arbeitsaufwand. Standardsysteme für Öfen bis zu 1350°C oder z.B. T6 Prozesse.



Thermprocess


Halle 9 Stand C59


TUS Messung für

AMS2750E und CQI-9



Universell!




Thermprocess


Halle 9 Stand C59


TUS Messung für

AMS2750E und CQI-9



Universell!




Thermprocess


Halle 9 Stand C59


TUS Messung für

AMS2750E und CQI-9



Universell!


NEWS Events

Supply of protective gas plants

Gebrüder Hammer GmbH plans and supplies systems to generate, purify, dry and analyse industrial gases,

protective gases, gaseous mixtures and special gaseous mixtures. The company was awarded the contract for the supply of a protective gas plant by one of the largest copper pipe producers in Malaysia. The copper pipes produced by the Malaysian customer are used worldwide in the air- conditioning and refrigeration industry.

The plant with a capacity of 300 Nm3/h supplies a pro-tective gas mixture of hydrogen, carbon monoxide, carbon dioxide and nitrogen. The mixture can be used, depending

on the mode of operation, both as a reaction gas and as a protective gas.

A new precious metal catalytic converter was used to lower the oxygen concentration. It enables the residual oxygen to be removed from the gas mixture without the addition of additional heat.

In order to ensure the highest possible availability, the piston compressors were designed redundantly. A newly developed treatment of the protective gas mixture upstream of the compressors reduces maintenance and thus the consumption of wear parts for the compressors.

By compressing the protective gas to 6 bar, it is possible to store the protective gas, which guarantees fully automat-ic power control that adapts to the respective customer requirements. The plant arrived in Malaysia at the beginning of March 2019 after a four-week ship voyage. Commissioning, staff training and handover to the customer followed in the following months.

Gebrüder Hammer GmbH www.hammer-gmbh.de Hall 9 / Booth A39

Individual planning of heat treatment equipment

Over the years, new needs of the ever-changing market switched the offer to a more and more customized

configuration. The Italian company Hi-Tech engineering is a manufacturer of customized heat treatment installa-tions, especially for those processes that require testing and engineering projects for the feasibility study.

The rapid changing needs of the customers demanded an immediate reaction of Hi-Tech, materialized in a con-crete organization of an indoor area for the research and development of its products.

No study is moved forward without feedback experience from the users of similar processes or without testing in laboratory. As no process is identical to another, no customer is equal to another and no requirement is always the same. For this reason, the same result could be achieved in different ploys always based on experience or testing. Hi-Tech’s aim is to focus on the request, pro-pose different solutions, discuss with the customer the best shaped one, improve that solution and fix it as a guideline.

Hi-Tech develops projects, designs, manufactures, installs and starts on production complete turnkey heat treatment installations both for steel and aluminium alloys: versatile roller type furnaces, modular batch type furnaces, different quench systems (water, water-polymer, oil, air, spray etc). Due to the more and more restrictive require-ments from the market, compliance with strict standards for construction and acceptance is a compulsory request that must be satisfied.

Hi-Tech engineering srl www.hitecheng.com Hall 9 / Booth D31


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Events NEWS

Heat treatment plants for different uses

The company IVR designs and manufactures furnaces and plants for heat treatment, electrical solutions for

a variety of industries, all completed by the after sales service.

IVR relies on a significant experience concerning the technical part and the heat treatment process, completed by high competence about energy-saving, environmental analysis and cost-cutting.

Recently, the company has developed an interesting project, together with the university of Padova, con-cerning the ReSiELP European Project (Recovery of Silicon and other materials from End-of-Life Photovoltaic Panels).

IVR believes that it is important to work closely with the customer at every stage of the project, to confront each other continually together and reach the goal within the set deadline.

The plants are suitable for various types of heat treatment, for example: gas carburizing, hardening with quenching in salt, water, oil and polymer; tempering; annealing; stress relieving; normalization; solution annealing; carbonitriding; nitriding, brazing, sintering, aluminium process T4-T5-T6.

IVR FURNACES www.ivrsrl.it Hall 9 / Booth B39

Newly developed endogas generator

Uttis Industries has developed a new series of endogas generators called Uttis Auto Gen. The new model

controls and manages automatically all process parame-ters, such as temperature, dew point, gas flowrate and air flowrate.

Unlike the standard type of generators, the newly developed endogas generator ensures the production of the exact amount of endogas as it is required. Thus, the user has significantly lower production costs and the gas flow rate adjustment does not depend on the operator anymore. When the heat treatment furnace is connected to the endogas pipe, the system detects and adjusts auto-matically the gas and air flow rates. During operation, the ratio between air and gas is constant regardless of external

factors. The risk of soot and having bad quality endogas is very low.

The new model may be implemented on existing generators by upgrading the system. It requires on-site interven-tion for max. three days.

UTTIS Industries SRL www.uttisheat.com

Hall 9 / Booth D25

Augmented support to be flexible and efficient

In addition to the fact that Wolfgang Kohnle Wärme-behandlungsanlagen GmbH has been manufacturing

and selling individual systems for a large number of heat treatment processes for almost sixty years, it will introduce a further elaboration for even better service and increase customer satisfaction in current projects. For this purpose, an augmented support concept has been developed which enables Kohnle to provide technical support worldwide in a short time.

Regardless of whether it is the purchase of a new Kohn-le system or the signing of a service contract for an older furnace system, customers can now take advantage of this additional service to receive even better and much faster

support. The modern and cost-efficient support of a user by a decentralized Kohnle expert forms the basis for this. The user on site receives the most detailed remote support from experts switched live via data glasses or mobile phone app. Based on encrypted, bidirectional communication from expert to user, service activities can be organized and guided decentral. With the integrated image tool, screenshots, photos and data sheets can be edited and transmitted in both directions.

Wolfgang Kohnle Wärmebehandlungsanlagen GmbH www.kohnle.de Hall 9 / Booth F74


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NEWS Events

Modular systems for integrated heat treatment

Specializing in manufacturing a range of customized industrial furnaces controlled under protective atmos-

phere, Codere is active worldwide in a number of fields, including the automotive, aeronautic, fastener, tooling, spring, precious-metal, medical, optical, armament and hydraulic industries, as well as serving a number of inter-national contract heat treatment shops.

The company specializes in the processes of hardening, case hardening, nitriding, tempering and annealing among various different quenching options oil, salt, water or polymer.

Codere has unique advantages against traditional batch furnaces. There has been growth especially in salt quench-ing processes (ADI, martempering, bainitic hardening),

titan treatment, aerospace projects respecting AMS 2750E or automobile (CQI-9) and multi product series (flexibility needed for temperature & atmosphere).

Currently the company is developing a new software, HT View, for new and existing installations. This new soft-ware will enhance control systems with optimization of production planning with several criteria, more detailed alarm settings, predictive maintenance function and a very operator-friendly interface.

Some advantages against traditional IQ batch systems are the flexibility of the system (two furnaces with one oil bath or two quench tanks working with one furnace in the same line) and the high-quality surface treatment of the pieces (important on long slim pieces). The modu-

lar system gives the possibility to meet future production by purchasing additional mod-ules. The system can heat up fast to working temperature in austeniti zing and carburi zing furnace and has easy and user-friendly maintenance. It is also fully automatic with non-stop production process inclu-ding nights and weekends from loading to storage on output station for treated loads.

Codere SAwww.codere.ch

Hall 9 / Booth C31

Atmosphere furnaces for metal heat treatment

The company Solo Swiss manufactures advanced indus-trial furnaces for the heat treatment of metals, used in a

variety of heat treatment processes: carburizing, hardening, tempering, annealing, austempering, nitriding, brazing, carbonitriding, sintering, nitrocarburizing, oxinitriding, quenching. Solo Swiss offers two types of furnaces:

Profitherm type batch furnaces: This unique, multi-functional arrangement of bell-type furnace and multiple quench tanks, allows a direct and rapid transfer of the load from the furnace(s) to the quench tank(s). The modular design enables easy expansions and allows all types of atmospheres and quench media.

Continuous furnaces: Featuring protective or treatment atmospheres with gas cooling or quenching in liquids.

All Solo Swiss furnaces are equipped with alloy muf-fles to provide precision heat treatment and feature quick quenching. Solo Swiss furnaces are well-suited for the treatment of the small complex metallic parts requiring an enhanced heat treatment and reduced distortion. Parts include springs, clips, fasteners, coins, needles, hooks, ball bearings, parts for the aeronautics, cutlery, watch-making industry, micro mechanic, as well as long parts for which the bell furnace is most suitable.

SOLO Swiss SA www.solo.swiss Hall 9 / Booth F26


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Modular heating system for induction forging

SAET EMMEDI Dyna Zone is a modular heating system for forging applications. It consists of identical independent

modules composed by a power generator connected to a single coil: each section can be controlled separately to fit any production rate. Modularity means high system flexibility, simplified maintenance, a single coil design, and less spare parts. Both series or parallel loads are supported.

The process temperature can be controlled with three different operation modes: manual, automatic, and adap-tive. Automatic mode is based on a predefined power- speed lookup-table: a feedforward closed loop controls the generator with temperature measurements.

The adaptive mode integrates a real-time estimator to predict the system behaviour in every configuration.

Changes in production rate produce new scenarios: diffe-rent data sets are calculated and transferred to the modules control systems. The pyrometers signals are compared with the modelled data and the filtered temperature values are used to control the power levels.

The Dyna Zone adaptive control system can also be used to perform offline temperature curve optimization with different targets like minimal energy or minimal core-surface temperature difference.

SAET S.p.A. www.saetemmedi.com Hall 10 / Booth F21


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Advertisement

FOCUS ON Edition 27

“As a global company, we hope to see the markets growing together”William Disler, President & CEO of AFC-Holcroft L.L.C. Here you can find AFC-Holcroft: Hall 9, Booth D15

How important is the trade fair THERMPROCESS for your company?Disler: Trade fairs have always played a key role in this industry and, of course, on a global level THERMPROCESS is the big one. This event provides a great opportunity for everyone involved in the thermal equipment and process industry to spend time sharing and absorbing information about the technology and market trends that impact all of us. For AFC-Holcroft and the entire Aichelin Group, we look at this as a great chance to showcase our latest innovations and to connect with our customers. It is very important for us to spend time hearing directly from our customers about trends they are experiencing so that we can continuously align ourselves to support their changing needs.

What products will you present at the trade fair in Düsseldorf?Disler: We plan on introducing a few new heat-treat equip-ment products as well as highlighting the incremental innovation of our core equipment. We might want to save the details regarding the new products for the show, but I can tell you that we have been listening to our customers. We believe that “hybrid” products that combine the posi-tive aspects of various technologies into new packages will capture the interest of our customers. We are also working on some Next Generation continuous equipment that is gathering momentum. People can count on seeing leading edge technologies in our booths that are reshaping the aftermarket service aspect of our heat-treat systems.

What trends and technologies are shaping the industry?Disler: A number of things are impac ting our customer’s needs. First, it seems that with each year that passes our customers are left with less time to adjust for capacity or process changes within their own businesses. This means that shorter deliveries, higher quality parts, and absolute part traceability are growing key drivers for our customers. In addition, our customers, and to be open the entire indus-try, continue to suffer from a lack of talent and experience in this industry. This transition within our industry is driving

demand for smarter systems and more service-based support from equipment manufacturers. AFC-Holcroft and the Aichelin Group have invested significant resources into developing new methods to help our customers be more successful operating their heat treatment equip-ment. You will hear more about Aichelin’s Jakob system that changes the way plants can support their furnaces. We will talk more about our Remote Diagnostics (RDX) capability and methods for customers to validate with us the ongoing health of their installed equipment. This area is one of the most exciting develop ment areas, as we can now combine equipment intelligence, IoT, and data filtering to truly impact equipment utilization for our customers. Higher uptime and utilization make our customers more successful.

Are you expecting new businesses to be generated at the trade fair?Disler: In the general sense, of course we expect that the exposure that we get at this trade fair will result in new business over time. It is interesting that as an American company, AFC-Holcroft has never looked at trade fairs as places where we actually take orders for new equipment. Of course, there have been exceptions, but this is not a major expectation for our participation. In the North American market, trade fairs are places where people network, attend tech-nical presentations, compare and absorb new technolo gies, and then usually take their notes back to the office to review and follow-up. We hope to have left the attendees with a good impression and that they


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will follow-up on project-specific needs at the appropriate time.

In Europe and a few other regions around the word, trade fairs are in fact places where deals are made. At these fairs there is often much more appointment schedu ling with customers who we have been working with for some time on projects and the meetings are used to finalize details and hopefully shake hands on a deal. This is appropriate, as we are all at the fair at the same time. I can recall securing a very nice new equipment order during the last THERMPROCESS fair. I would welcome the same experience this year.

How do you evaluate the business climate in general?Disler: I think that this year we need to break down the business climate into regions. Throughout the last year, we have seen some of the most unpredictable market conditions that I can remember. In the North American market, the political, trade, and tariff disruptions were greatly increased. Following healthy tax relief which was welcomed by businesses, companies were immediately thrown into the uncertainty of what trade agreements

between the USA, Canada and Mexico would look like. Steel tariffs impacted our entire industry, especially our end users that make metal widgets. Major capital investment decisions were affected by this uncertainty. Now we see the North American market starting to stabilize and we are hopefully seeing the benefits of a continued, strong US economy with 3 %+ GDP growth.

As we see this positive feeling starting in North America, the European market has dipped into tougher times with capital investment slowing significantly. At the same time India is a very strong market and China, although slowing, is still a growth area. As a global com-pany, we always hope to see all of the global markets growing together. It never seems to work out that way. At least we are not seeing all global markets slowing. It is reassuring to me to know that AFC-Holcroft and the Aichelin Group have the diversity to manage through all of the peaks and valleys that the heat treatment equipment industry can throw at us and always come out stronger. We see exciting times in the future for all of us. We are looking forward to supporting our customers’ growth around the world with innovation and support.


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INTERVIEW

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NEWS Events

Induction hardening machines for large rolls

Salus is a Slovenian machine-building company located in Ravne, where the steel industry has 399 years of

tradition. The company designs and produces only on order, custom-designed induction hardening machines, quench tanks, cryogenic freezers, parts and components for heavy machinery.

The company’s dual-frequency arrangements using two different power suppliers and two different frequen-cies are needed to achieve the desired hardness profile of large and massive parts where larger case depths are necessary. Salus dual-frequency induction hardening machines provide deep penetrating heat and make it possible for their customers to launch a new generation of induction-hardened large rolls (hardening depths up to 60 mm), also HSS rolls. The whole induction hardening process is automated and computer-controlled. These machines also enable the rehardening of used rolls and the preheating of rolls. For improving the quality of the hardened layer after the induction hardening, they designed the cryogenic freezer for sub-zero treatment.

Salus turnkey solutions for induction hardening of large rolls, roll necks, raceways, gear teeth etc. are tailored to the specific requirements of the customer and de veloped for maximum effectiveness.

SALUS d.o.o. www.salusdoo.si Hall 9 / Booth A16

Industry 4.0 solutions in metal heat treatment

Various industries are currently experiencing unprece-dented changes. Emerging technologies open new

doors, but on the other hand, pose a challenge. What are the challenges and what is the Industry 4.0 in the world of metal heat treatment? Seco/Warwick will show its latest technology advancements and newest products during THERMPROCESS.

The trade fair is a huge event, during which you cannot miss equally large and exciting product announcements. Apart from current flagship products, Seco/Warwick is going to show new ones: SuperIQ and UCM 4D Quenching, tech-nologies that suit the most demanding industries. SuperIQ is a combination of key properties. This is a universal chamber furnace of the latest generation with an integrated quench-ing system, combining the attributes of a conventional and vacuum furnace in one. It is therefore a hybrid of both tech-nologies, offering a unique type of heat treatment.

In turn, UCM 4D Quenching is a system that minimizes common and annoying hardening deformations thanks

to the use of a chamber dedicated to individual details, equipped with an omni-directional, nozzle cooling system in gas with simultaneous rotation of parts.

Along with new product announcements, Seco/Warwick will present systems that improve production performance by leveraging innovations and implementing the newest available technologies in intelligent tool development. These tools, Seco/Predictive (an advanced, intelligent device control system that can detect potential failures before they occur) and Seco/Lens (AR application for monitoring, diagnostics, maintenance of the production process, remote repair and planning the most optimal layout of the production line on the hall), enhance manufacturing processes through the use of AR, AI, IoT and latest Industry 4.0 concepts.

SECO/WARWICK S.A. www.secowarwick.com

Hall 9 / Booth C26


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Heat Treatment/ Induction Technology – PRODUCT PREVIEW

Events NEWS

Modular hard-and software platform

As a company owned by the Inductotherm Group, specialized in inductive heating, the intension of

Inducto heat Europe is to help their customers continuously increasing their performance. The new developed I-syst 4.0 underlines this pretension.

I-syst 4.0 is a modular and system-independent hard-and software platform which offers different advantages, such as parameter documentation and control (adjustable onto customer’s requirements), quality control based on envelope monitoring, machine parameter monitoring in real time inclusive free definable benchmark and energy management system including peak load monitoring. Furthermore, automatic inverter adjustment, maintenance tools, e. g. manuals, remote access, status request, main-tenance interval monitoring and maintenance logbook, and data interface for further use of all data within the operation unit at the customer’s plant.

The system is based on a machine type and brand indepen-dent basic hardware based on OPC server and a basic software. This system can also be retrofit easily on existing units inde-pendent of their brand. Only the customer must decide which option and or function he will use in his machine in future.

Data are very valuable and sensitive, so it is important that the customer keeps 100 % control over his data. Based on that, all received and processed data will be stored and available within the machine system only – means machine is offline.

Remote access functions will be started unexceptional with approval from and initiated by the customer. That guarantees highest customer safety standard.

Inductoheat Europe GmbHwww.inductoheat.eu

Hall 10 / Booth D42

IGBT converters with digital control system

EMA Indutec GmbH was founded over 73 years ago. Since then, the company has been developing new

ideas and products for various inductive applications in various fields such as heating, forming, forging and melting both in crucible and channel furnaces. Over the past few decades, the company based in Meckesheim, Germany, with more than 150 employees, has developed reliable and efficient products for companies worldwide.

The portfolio consists of a number of products, inclu-ding the modern IGBT converters. The core competence of

the EMA converter is the digital control system ZVE, which handles all control, regulation and protection functions of the converter depending on the application. The large number of integrated interfaces allows the connection to current bus systems, controllers and other components.

EMA Indutec GmbHwww.ema-indutec.de

Hall 9 / Booth E26

Hall 10 / Booth E74

ITG develops smart cooling water management

ITG Induktionsanlagen has become established in the upper performance range of frequency converters for

inductive heating. This specifically includes the technical innovation of customer-specific product heating with a total output of 42 MW, divided into individual powers of 3 and 6 MW.

The task was replacing an existing gas furnace with a flexi ble and energy-efficient solution. Project processing and implementation were completely implemented by ITG – from small-format lab tests at ITG, to preliminary stages for process validation, to implementation of the production system.

The improvements of converter technology focused on the power components in order to meet the global

requirements concerning “Green Economy“. In this con-text, a smart cooling water management was deve-loped to potentially cut cooling water consumption in half.

The innovative technical overall solutions of ITG comprise all components for inductive heat treatment and complex turnkey projects – customized and living up to the highest demands.

ITG Induktionsanlagen GmbH www.itg-induktion.de Hall 9 / Booth C02


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PRODUCT PREVIEW – Induction Technology

NEWS Events

IoT platform for process analysis in the metal industry

Achenbach Optilink is the IoT platform developed by Achenbach Buschhütten for the metal industry. The

company, producer of rolling mill technology in the alumi-nium and non-ferrous sectors, recognized comparatively early the great potential of using WEB technologies for process analysis. Together with partners from the IT world, the ‘Scitis portal’ was developed, adapted for the metal industry and supplemented by industry-specific ‘apps’. Thus, the work of production managers, process engineers and maintenance personnel can be simplified respectively supported by the intelligent, real-time analysis results of the portal today.

Optilink’s strengths are firstly the small effort involved in connecting a plant control system to the portal, secondly the sophisticated security concept and thirdly the data model which makes it possible to perform even complex analyses on huge data amounts in a short time. Especially when data from different single systems or even from diffe rent corporate networks are to be processed together Optilink shows its quality: By tracking production units through the entire rolling process, high-resolution data can be used

early to identify weak points and prevent costly late effects. Also, when using the approach only on a single machine, Achenbach’s customers were able to achieve significant efficiency gains through the use of Optilink. Last but not least, the application of automated learning methods on real, continuously injected production and quality data is on this basis cost-effective and easy to implement. By an Optilink demonstrator the Achenbach exhibition team will show interested booth visitors the function, use and examples for tailor-made dashboards.

Further main topics are the lifecycle support for rolling mill and slitting machinery, a 3D simulation appli cation for virtual commissioning of technical solutions as well as the presentation and exhibit of new technology components as the Achenbach UniSpray Nozzle Bar with BUS system or the Achenbach UniFlat CFP Flatness Measuring Roll.

Achenbach Buschhütten GmbH & Co. KG www.achenbach.de

Hall 4 / Booth C19

DVGW-certified valves for gas applications

With its angle seat and sliding gate valves, Schubert & Salzer Control Systems provides a range of highly

precise and DVGW-approved control- and shut off valves for gas applications.

The very reliable shut off valves type 7010 are certified by the DVGW in accordance with DIN EN 161 for gas applications and available in nominal size of DN8 to DN65. The sliding gate valves, certified in accordance with DIN EN 16678, can be used for highly precise control tasks such as natural gas and oxygen applications in combus-tion and firing installations or burner applications.

Sliding gate valves are characte-rized by their excellent control quality, compact design and low weight. In particular, the very good response of the sliding slide valves is crucial for the high control quality. For a very short response time, the short stroke, low moving masses and low actuation

forces are the most important parameters. All of these properties are combined by the sliding gate valve. The typical stroke between “open“ and “closed“ is only 6 to

9 mm. Sliding gate valves are manu-factured with p/p-, i/p- and digital positioner (type 8047 and type 8049) even in explosion-protected version with the current DVGW certifi cation in the sizes DN15 to DN150, for pressures up to PN 40 and for fluid tempe ratures from -60 to +350 °C. The certification covers type GS1 sliding gate valves with both pneumatic diaphragm actuator and pneumat-ic piston actuator. Consequently, all sliding gate valves of the 8021, 8043 and 8044 series are covered by the new DVGW certification.

Schubert & Salzer Control Systems GmbH www.schubert-salzer.com

Hall 9 / Booth C25


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Measuring & Process Control – PRODUCT PREVIEW

Events NEWS

Temperature control in metal and plastic processing

Exact temperature control is a critical factor in many industrial metal and plastic processing

sequences. In these scenarios, the requirements regarding temperature control can vary substan-tially depending on the production conditions. However, what is always required are solutions that guarantee 100 % repeatability wherever pos-sible to ensure high product quality. They must also be simple to integrate and capable of being extended or converted as required. The modu-lar temperature control platform developed by Bürkert Fluid Control Systems, which permits seamless adjustment to suit the most varied pro-cesses, was designed with these requirements in mind. It is based on a broad range of electro-motive and pneumatic valves as well as various measurement principles, e. g. for coolant flows (ultrasound and paddle wheel), air quantities (thermal sensor) as well as pressure and tempe-rature. Supplied as a custom assembled complete system, the temperature control can then easily be integrated into the most diverse applications.

Thanks to the modular design, individual valve clusters can be realized, as can multi-channel media distribution systems or complete media cabinets – always adapted to meet individual requirements. The user avoids the need to install piping between individual valves and dead spaces are reduced thanks to the compact design. In contrast to discrete assembly solutions, this allows the valve block to be placed close to the tool. Since the compact design also reduc-es the heat-radiating surfaces, energy efficiency improves accordingly. The service-friendly structure also makes it easier to replace indivi-dual components. Orbital welding seams and high-temperature graphite seals that can also

withstand extreme temperature differences guar-antee leak-free operation.

The Bürkert EDIP (Efficient Device Integration Platform) can be used to connect the tempera-ture control to all standard bus systems; the wiring complexity is reduced; start-up and para-meterization are simple. Depending on the tool and process, temperatures can be specified, the flow control set automatically, or a constant pressure maintained. Once parameters have been stored, they can be restored at any time. All things considered, the temperature control processes are reliably repeatable which boosts product quality and eliminates waste.

Bürkert GmbH & Co. KG Fluid Control Systemswww.burkert.com

Hall 10 / Booth A74


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PRODUCT PREVIEW – Measuring & Process Control

FLEXIBLE BATCH CAR BOTTOMHEAT TREATING SYSTEMS

PRECISION AIR QUENCH(PAQ)SYSTEMS FORALUMINUM

CONTINUOUS MESHBELT ATMOSPHEREFURNACE SYSTEMS

PLATE HEATTREATING SYSTEMS

ALUMINUM STRUCTURAL COMPONENTS HEAT TREATING SYSTEMS

BASKETLESS HEAT TREATING SYSTEMS (BHTS®)

ROTARY HEARTH HEAT TREATING SYSTEMS

CONTINUOUS BAR PRODUCT HEAT TREATING SYSTEMS

CAN-ENG FURNACESENGINEERING SOLUTIONS TO LAST

To learn more about CAN-ENG Furnaces International Limited’s Engineering, Design & Manufacturing capabilities please visit us at

GIFA in Düsseldorf, Germany, June 25 - 29, 2019 stand10C69,www.can-eng.com or email [email protected]

CAN-ENG Furnaces International Limited is a leading designer and manufacturer of thermal processing solutions. With 50 years of experience and installations worldwide, CAN-ENG

understands your business and its unique demands.

P.O. Box 235, Niagara Falls, New York 14302-0235www.can-eng.com | T. 905.356.1327 | F. 905.356.1817

Advertisement

NEWS Events

Central processing unit with new hard- and software platform

JUMO is starting a new era of automation with the JUMO variTRON 500 central processing unit. In terms

of technical possibilities, the system plays in the top class of embedded systems and proves itself with the high-speed performance and flexible operating philosophy.

For the first time, a completely new hardware and soft-ware platform is being used in the JUMO variTRON 500. During its development, scalability had the highest priority. The result is modular, flexible, and, above all, sustainable. The basis of the JUMO variTRON 500 is a hardware platform

with an 800 MHz processor which can be used as a single, dual, or quad core variant depending on the application.

The software has a modular structure based on a Linux platform and enables excellent scalability for performance, memory, and interfaces. Another special feature is a customer-specific configuration and process data editor.

Several operator stations can be integrated into the system via Codesys TargetVisu or Codesys WebVisu as well as up to 64 intelligent connection modules.

In the future, JUMO will provide visualization libraries for individual customer-specific operation via Codesys TargetVisu or Codesys WebVisu. Flexibility is also made possible by the integration of all-important fieldbus systems via Codesys (such as Modbus RTU or TCP master and slave, Profinet IO controller, EtherCAT master, and OPC UA server).

In the future, a Profinet IO device interface will allow an alternative connection to higher-level control systems via Modbus TCP.

JUMO GmbH & Co. KG www.jumo.net

Hall 10 / Booth G60

Bus module units simplify thermal process control

The BasicBusModule series are modular, easy-to-use bus module units for cost optimization of up to eight SCR

power controllers from Advanced Energy’s (AE) Thyro-S, Thyro-A, or Thyro-AX series.

The BasicBusModules are available with or without optional dASM functionality. The dASM feature allows optional mains load optimization for up to 32 power control-lers in Takt (full wave switch) mode. The new bus module has an external power supply of 24 VDC / 200 mA per module.

With different available common fieldbus communi-cations by using the Anybus interface, it allows a simple integration and provides access to all connected SCR power controllers for full parameter access with Thyro-Tool Pro software via integrated USB interface.

In combination with AE’s standard Thyro-S, Thyro-A, or Thyro-AX SCR power controller series, it serves in all high-tech and industrial applications for electrical heating, melting, drying and forming, hard coatings, display technologies, IR drying and more.

Advanced Energy Industries GmbH www.advancedenergy.com Hall 9 / Booth C60


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Events NEWS

EcoStruxure platform for simplifying the digital transformation

Eurotherm by Schneider Electric work within the digi-tal transformation of energy management and auto-

mation. At THERMPROCESS, they take visitors on a digital journey which is easier than you may think. With experience and expertise, digitalization does not have to be expensive, nor does it have to be accompanied by business inter-ruption or complex and complicated integration of new technologies.

The EcoStruxure™ platform is the digital backbone connecting best-in-class operational technology (OT) solutions with the latest in IT technology to unlock trapped value in your operations and leverage the true potential of the Internet of Things. These capabilities allow the discovery and onboarding of connected products configuration and messaging with devices, the collection and storage of device data, the ability to perform local analytics and easy configuration and upgrades at a device level.

EcoStruxure Manufacturing Compliance Advisor is a tool to efficiently manage compliance and calibra-tion requirements. The platform is designed to aid cost reduction, increase productivity and always be ready for an audit thanks to an unusually robust test and approval process. Ultimately, this leads to greater energy efficiency and better test productivity, which then helps in reducing

operating costs and maintaining compliance to regu-lations.

Put real-time information at your fingertips, when-ever and wherever it is needed. The custom application improves operational efficiency with augmented reality, enabling operators to superimpose their current data and virtual objects onto a cabinet, machine, or plant.

Power Monitoring Expert gives insight into electrical system health and energy efficiency, so you can make informed decisions to improve power system performance. With its open, scalable architecture, PME connects to smart devices across your electrical system – power and energy meters, protective relays and circuit breakers, RTUs and PLCs, VSDs, UPS, and PQ mitigation equipment – and integrates with process control systems and many other enterprise platforms.

“Schneider Innovation at Every Level is helping our custo mers to save time, energy, and money every day,” said John Doe, Vice President of Innovation.

Schneider Electric Systems Germany GmbH >EUROTHERM< www.schneider-electric.com Hall 9 / Booth E24

Temperature monitoring for metals and steel

Fluke Process Instruments presents its range of ther-mal profilers and infrared temperature measurement

solutions at the THERMPROCESS trade fair. The latest addition to the IR pyrometer portfolio, Thermalert 4.0, enables automatic non-contact temperature monitoring in a -40…2,250 °C range. Due to the outstanding ambient temperature range of -20…85 °C, more measuring points can be set up without cooling.

Another IR innovation, the industrial-grade thermal imager ThermoView TV40 with an integrated visible-light camera, is also on show. The fixed-installation thermal camera enables 24/7 temperature monitoring in a -10…1,200 °C range. Developed to meet today’s demanding industrial automation requirements, it supports GigE streaming of images and automatic alarms.

The manufacturer’s thermal profiling systems are represented by Datapaq TP3 data loggers, featuring up

to 20 thermocouple channels and outstanding 3.6 mil-lion data points memory capacity. The loggers enable temperature uniformity surveys (TUS) and in-process product temperature monitoring. Even water or gas quench processes can be profiled. Users can easily cus-tomize reports and generate CQI-9, AMS 2750E, and ISO9000-compliant reports. The measured temperature range is -100…1,370 °C with a ±0.3 °C accuracy. Fluke Process Instruments offers complete application-tailored system solutions including resilient thermal barriers, Datapaq Insight analysis software, and thermocouples. The team will be happy to advise visitors on the best way to tackle their particular application.

Fluke Process Instruments GmbH www.flukeprocessinstruments.com

Hall 9 / Booth C73


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NEWS Events

Software applications for process optimization

The trend to an ever-increasing flexibility in produc-tion along with a broader product mix and smaller

production lots as described in Industry 4.0 scenarios is a recent challenge for the steel industry. Growing customer requirements regarding product quality is another one. In addition to that, improving energy efficiency and reducing carbon dioxide emissions is becoming more and more important. With Celano’s software solutions companies can face all these challenges.

Since 2002, the company provides software applications for the optimization of production processes with a team of engineers, mathematicians and computer scientists. With the new version of its own IT-framework for the industry celCAP 4.0 Celano is ready for use in Industry 4.0. Smart devices like tablets and smartphones are supported as well as wearables like smart watches or smart glasses. Based on this versatile and reliable framework the solutions range from MES and SCADA systems for steel plants, hot and cold rolling mills and finishing lines on the one hand to optimization systems on the other hand. The FurnaceCon-trolSystem celFCS is an example for process optimization. It can be used for nearly any kind of industrial furnace due

to its universal approach. It is based on a three dimen-sional thermodynamically model which allows calculating the temperature deviation of the whole material in the furnace. The benefit for the customer is a lower energy consumption, a standardization of the furnace operation independent of the operator and a higher mix of different product qualities he can produce in the furnace.

On the example of a cooling bed for plates a new online material flow optimization for critical conveyance infra-structure will be presented at the ESTAD conference as well as the results of the research project “DamokleS4.0- Dynamic, adaptive and mobile system for context-based and intelligent support of employees in the steel industry”. This project explores how new technologies, like mobile and smart devices or augmented reality as envisioned in Industry 4.0, can be used to provide context-based and intelligent support to employees in the steel industry.

celano GmbHwww.celano.eu

Hall 10 / Booth F20

Optimizing thermal processes with ThermoOptical measuring systems

High savings in throughput and energy consumption still exist for most heating processes, which have been

empirically optimized. At the same time, often the product quality can be improved. This is because many process parameters exist which are strongly correlated. Thus, trial and error methods or conventional techniques of design of experiments are inefficient.

At Fraunhofer-Center for High Temperature Materials and Design HTL in Bayreuth, a methodology was developed, which allows a targeted optimization of thermal processes. On the one hand, the industrial furnace is measured using a mobile test rig and on the other hand the heat treatment process is reproduced in specially developed ThermoOptical measuring systems (TOM) on a laboratory scale. Thereby, the atmosphere of the industrial furnace is matched and all mate-rial data relevant for process optimization are measured in situ.

The measurement data are parameterized and integrated in a robust finite element model of the heat treatment process. On the computer, the heat treatment is simulated and optimized. The scale-up to the production furnaces is performed first virtually. After validation of the simulation

results on the lab scale, the optimized process parameters are transferred to the real process. In general, improve-ments in throughput and/or energy consumption by at least 20 % are achieved. In many cases, also the rejection rate has been lowered significantly.

The HTL already has experience with the optimization of drying, debinding, pyrolysis, sintering and melt infiltra-tion processes. In various in-situ measuring systems all relevant atmospheres can be realized from air and inert gases to hydrogen and combustion gas atmospheres, from vacuum up to a pressure of 30 bar. Depending on the atmosphere, temperatures up to 2,200 °C are reached. In addition to the temperature cycle and the furnace atmosphere, also the stacks are optimized. If necessary, the refractory materials used in the heat treatment process can be investigated and optimized as well.

Fraunhofer-Center for High Temperature Materialsand Design HTL www.htl.fraunhofer.de

Hall 9 / Booth C09


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Events NEWS

Pilot-operated gas pressure regulators

With the new pilot-operated gas pressure regulators series RSP254/255 from Medenus Gas-Druckregel-

technik GmbH it is possible with a maximum inlet pressure of 16 bar to realize outlet pressure from 10 mbar up to 12 (14) bar. With this systems you can achieve very high accuracy up to 1 % and therefore it is applicable to the very high requirements of your applications.

With the pilot system R70-100 the low pressure range from 10 to 500 mbar is covered, with the R70-10 you can handle the range from 500 mbar up to 12 bar and the R70-20 system is applicable to special applications such as I/P converter systems for manufacturers of gas engines. In this applications you can adjust the outlet pressure with I/P converters and the integrated 1:2 booster remotely and up to 14 bar outlet pressure.

The regulators have a very high corrosion class due to the used aluminium alloy up to C5-I and it is possible to add a special coating if C5-M is required.

The pilot operated regulator series RSP254/RSP255 are available in nominal sizes DN25 to DN200 and equipped with flanges to DIN EN 1092 standard or to ASME B16.5 Class 150RF. They are available with integrated safety shut of valve or without, called RP254/RP255.

The standard delivery time as for the entire program of Medenus is two to three weeks. If the devices are needed

faster, it is also possible via the express production rail within one week.

MEDENUS Gas-Druckregeltechnik GmbH www.medenus.de Hall 9 / Booth A34

Temperature measuring system used directly in the furnace

In heat treatment processes up to 1,000 °C or more, often under certain atmospheres or conditions such as nitrogen

or vacuum, it is very difficult to determine the actual tem-peratures at and in the product. This is where PhoenixTM comes into play: with the temperature measuring sys-tems, for example the TS02 series, the temperatures can be measured directly in the furnace, at the product or the measuring rack, recorded, stored and, if necessary directly via radio transmission, seen and evaluated. Special materials and a sophisticated construction to avoid excessive distortion allow regularly measurements with exact results even in processes with gas quenching or aggressive atmospheres.

Other series, such as the TS12 systems with their 2-stage insulation, can go through the complete carburizing process, including the oil quench bath. So not only the temperatures in the furnace, but also the heat transfer in the quenching bath become visible. Steam bubble forma-tion or insufficient flow can be detected and optimized.

In turn, the TS06 series is capable of measuring processes with liquid media, such as the water bath during annealing of stainless steel or in solution treatment processes of alu-minium. Through the water evaporation technology, the system can measure the complete process from solution treatment to quenching and the hot aging furnace. This gives the user a complete and informative overview of the actual product temperatures and can measure very easily, regularly and reproducibly according to quality specifica-tions and standards.

With the ThermalView Survey Software, the user receives a complete AMS2750 or CQI9 evaluation. With just a few clicks, detailed analyzes for audits and quality assurance processes can be provided.

PhoenixTM GmbH www.phoenixtm.de

Hall 9 / Booth C59


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NEWS Events

Advanced materials in carbon and graphite

Advanced Graphite Materials offers its customers effec-tive solutions in carbon and graphite to meet their

demanding needs. For over 130 years, the company has provided advanced materials and broad-based solutions developed for the manufacture of iron, steel and metal products. These are finding a variety of applications in the solar, nuclear, oil and gas, defense and aerospace industries.

The product portfolio includes extruded, pressure or isostatically pressed carbon and graphite materials, carbon or graphite insulation, carbon or graphite foam and carbon or graphite powder. The company produces in America and the materials are processed into customized solutions in the plant in Italy.

Grafstar Advanced Graphite is a choice for customers in various industries with demanding applications requiring high strength, low thermal expansion and superior conductivity.

Grafshield industrial high temperature hard and soft felts control radiant heat, thermal conductivity and convective heat with compact, lightweight and durable insulation components. They are designed to help customers improve their performance and profitability by reducing their energy and maintenance costs.

Advanced Graphite Materialswww.agmwv.com

Hall 9 / Booth C16

Refractory anchoring systems

Silicon was started in 1982 with the goal to service the refractory industry with special refractory anchoring

systems, which holds in place a special insulation to contain the heat energy that the process needs to accomplish a certain (chemical) reaction or effectuate certain properties in materials. This heat energy can manifest itself from tem-peratures ranging as low as 200 to 1,800 °C.

Because of the high temperatures encountered in this industry, wear and tear, corrosion and metal fatigue deter-mine the life time of the metal alloy. The furnaces that we concentrate on are typically furnaces for the refining of crude oil, its sub products and furnaces in the cement and steel industry. The numbers of refractory anchors that can be used in any such furnace are anything between 1,000 and 100,000 pieces.

The company offers 37 years of experience with high-quality products, fast delivery time thanks to large stocks of various high-temperature alloys like 310, 330, 800, 601 and 625 in round or flat bars, plates and round wire, and cost-effective prices. Our innovations have been made possible by discussions with our customers

and by being focused solely on solving their refractory problems.

So, Silicon is a one-stop shop for anchor design for better life time as well as high quality anchor production and associated products for brick / concrete / dual and ceramic fiber linings.

SILICON RAS BV www.silicon.nu

Hall 9 / Booth D49


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Materials & Refractories – PRODUCT PREVIEW

Mica products for electrical insulation

The company ISO-tech Belgium is specialized in mica insulating products. What is mica? As a mineral essen-

tially made of aluminosilicate and potassium, natural mica is extracted in India, China, Brazil and Madagascar among others. Thanks to its electrical insulation pro-perties, strong thermal resistance, non-toxicity and low

footprint on the environment, mica is to be found in many applications such as domestic appliances, specific cables, high voltage engines, the automotive and space industry, iron and steel mills or even cosmetics (shiny effect on lipsticks for instance) and decoration (paint), and so on.

Events NEWS


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PRODUCT PREVIEW – Materials & Refractories

High reinforcing needle content

Allied Mineral Products develops, designs and manu-factures monolithic refractories. The company shows

presence with manufacturing facilities and sales represen-tatives in over 100 countries. Their domestic and internati-onal capabilities include the foundry, industrial, aluminium, steel, heat treating and forging industries.

Allied provides service, solutions and products to meet specific refractory needs. The product Armormax has been field-tested in various applications and shown to improve furnace performance and reduce refractory consumption. It can withstand repeated thermal cycling, mechanical impact and abrasion due to its high reinforcing needle con-tent. High reinforcing needle content means Armormax can

withstand the toughest task a furnace has to offer because the needles are pre-blended and uniformly distributed throughout the refractory matrix.

Armormax is formulated for applications up to 1,315 °C (2,400 °F) continuous exposure. It is also characterized for low water requirements, ranging from 4.5 to 6.5 % by weight. In addition to its high fracture toughness, low abrasion loss and high mechanical impact resistance, it features flowability properties for a high needle-bearing refractory castable.

Allied Mineral Products, Inc.www.alliedmineral.com

Hall 10 / Booth C39

ISO-tech Belgium closely collaborates with the iron and steel mills, particularly the foundries that melt using induction furnaces in which mica is practically vital for the electrical insulation.

The ISO-Flex products are specially designed for the metal casting industry to separate the refractory linings from coils in induction furnaces. The barrier created by the ISO-Flex products provides protection against carbon gases and protects the inductor coils from expansion and contraction forces caused by thermal gradients. The ISO-Flex products also provide electrical insulation between the coil and the molten metal, optimizing the heat flow and preventing leakage and costly damage to the coil.

The most used of these products is the home-made ISO-Combi (lamination of bio-soluble fiber and mica paper). It has a very low degree of thermal conductivity (0.14 W/°Km at 800 °C).

The selected bio-soluble fiber paper is 100 % toxic free and does not require any specific protection for handling. Mica is reinforced with glass cloth for a better tensile strength during handling and application.

ISO-tech Belgium SPRL www.iso-tech.be

Hall 10 / Booth A 67

Control the temperature, the power — and your costs

Advanced Energy Thyro-Family SCR power controllers offer precise advanced process control for demanding thermal applications with voltages from 690 V and currents from 2900 A.

Non-contact temperature sensors for improved process monitoring and greater efficiency

LumaSense Technologies Mikron MCS640 is a short wavelength infrared (SWIR) digital thermal imager designed to accurately measure temperatures from 600 to 3000 °C — e.g., for measurements on metallic surfaces, graphite, and ceramics.

ISR 6 and IGAR 6 Advanced are digital, 2-color pyrometers for many measurement applications. The wide accessory range optionally includes integrated line optics for wire production and pouring stream measurements.

Visit us during Thermprocess 2019 at Hall 9 Booth C60

advancedenergy.com

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FOCUS ON Edition 27

“Technological progress creates a favourable business climate”Sławomir Woźniak, Deputy CEO of Seco/Warwick S.A. Here you can find Seco/Warwick: Hall 9, Booth C26

What is the significance of GIFA, METEC and THERM-PROCESS trade fairs for your company?Woźniak: Every four years, the trade fairs define and set the direction of the metal heat treatment market. Hence, it is not only an opportunity to exchange experiences, but a place to present the company’s achievements. They often pose a challenge for traditional methods, applying numerous systems that maximize energy efficiency, reduce costs, and streamline production processes. Seco/Warwick will present solutions that are unique on a global scale.

What products are you going to present?Woźniak: In addition to our best-sellers, we plan to present two new products: SuperIQ and UCM 4D Quenching will be launched. These two solutions suit the most demanding industries. SuperIQ is a combination of key features. It is a universal chamber furnace of the latest generation, with an integrated quenching and carbonizing tank, combining the attributes of a conventional and vacuum furnace. Thus, it is a hybrid of both, offering a unique heat treatment.

UCM 4D Quenching minimizes quenching deformations, due to the use of a chamber dedicated to individual details, equipped with a system of cooling in gas medium with omni-directional nozzles and simultaneous rotation of parts.

What trends or technologies are shaping the industry?Woźniak: Augmented reality, algorithms supporting the decision-making process, predictive maintenance systems, repairs, workshops and cooperation in different time zones, AI and IoT usage in production processes. These are only some of the factors and trends that make up Industry 4.0.

Seco/Lens is an example of this approach. It uses aug-mented reality (AR) technology for remote repair, monitoring, diagnostics, as well as planning the most optimal layout of the production line. It allows for an accurate visualization and for conducting device operation training without the need for expensive and time-consuming travel. It is worth adding that it is the first such application in Poland and one of the first in the world for the use in heavy industry.

Another system is Seco/Predictive, a device control sys-tem that can detect potential failures before they occur.

Unforeseen production downtime means billions of dollars of lost revenues. The task of Seco/Predictive is to predict failures that previously seemed unpredictable.

‘Heavy industry does not have to mean heavy thinking’, this is a slogan reflecting the strategy chosen by Seco/Warwick. The company has developed many tools using artificial, augmented reality, IoT.

The booth will also be kept in this way: In order to see the solutions, visitors will use AR technology and scan dedi-cated markers. Thereby, the product will be visualized in 3D.

What do you expect from this trade fair?Woźniak: In 2015, Seco/Warwick presented a new strategy called ‘Invention meets Reliability’. Now we prove what it means that inventiveness meets reliability and efficiency.

In our opinion, innovation is adapting a technolo gical solution or a way of managing to a new reality, other expectations of the industry and customer, or changing environmental standards. This approach is a driving force in the implementation of R&D projects, such as the analysis of construction and technological issues or process optimiza-tion and implementation of achievements of science and technology. This is the direction we will present this year.

How do you evaluate the business climate?Woźniak: To put it in one word – posi tively. Our financial results con-firm this. A significant increase in sales and a record order portfolio show that last year was very successful.

Technological progress creates a favourable business climate. How ever, this often forces to change the business model and shows that only those will survive who adapt to these changes, providing solutions where innovation meets reliability.


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Events NEWS

Eco-friendly refractory monolithics

At GIFA 2019, Seven Refractories represents its latest developments in terms of refractory monolithics:

Taphole clays are specifically designed to achieve optimal performance despite utmost reduction of some noxious com-ponents. Seven develops alternative resin binder solutions to ensure the lowest possible concentration of potentially harmful compounds such as Polycyclic Aromatic Hydro-carbons (PAH).

Some of the biggest and most advanced blast furnaces in the world are running on Seven taphole clays. To date, more than 50 blast furnaces on four continents have been supplied with Seven’s environmentally gentle taphole clay, some as large as 5,500 m3 volume or 12,000 t per day.

Each taphole clay ensures optimum performance and customized workability: High alumina raw materials keep high mechanical strength, making the product suitable for contact with liquid metal and slag occurring at the highest levels of furnace productivity. Speedy curing guarantee the perfect holding of the closed taphole, whether in alternate casting or during back-to-back operations in consecutive casting.

Constant product quality monitoring and 100 % logistics traceability of raw materials, production process, and delivery ensure an optimum product profile at all times. Each Seven taphole clay is packed in sturdy cardboard boxes on wooden pallets, all individually PE wrapped. The packaging is specifically designed to permit stacking of up to four pallets, with space-saving benefits in warehouse storage. The box opening system allows for easy ergonomi-cally correct access and handling of the pieces.

Some of the most modern steel plants in the world have been successfully supplied with Smooth Solutions by Seven Refractories, both for cast and flow technologies. Over the past years, traditional brick solutions have become less economically viable: The price of bricks has sky- rocketed, challenging plant managers and sourcing experts alike. As a close partner of major steel producers, Seven Refractories has worked intensively to develop alternatives to traditional bricks.

Seven has successfully supplied a variety of safety linings and working linings for ladles ranging from 8 to 400 t in capacity, sometimes resulting in a considerable expansion in lifetime and an increase in heats. Customers profit from monolithic Smooth Solutions both in terms of cost reduc-tion and technological advances.

High resistance to steel and slag contact, compatibility with all the used covering powders, abrasion resistance, high mechanical strength, all coupled together with an enhanced ease of installation, make Seven Smooth Solu-tions an all-round material for the requirements of the modern steel plant.

When the walls of a ladle are installed with monolithics instead of bricks, a thinner refractory layer can potentially be the result, thus increasing the productive inner volume of the ladle.

Seven Refractories d.o.o. www.sevenrefractories.com Hall 10 / Booth C60

Advanced materials for high-temperature applications

The German-based QSIL is an international provider of high-performance materials, specialized in the produc-

tion of quartz glass and oxide ceramics.Fused quartz is an excellent material for high-tempe-

rature applications with a long-term usable temperature of 1,100 °C. The sole focus of QSIL is the manufacture of fused quartz, including the fusion of heavy wall cylinders, small and large diameter tubes and the fabrication of customized products. QSIL has a high degree of flexibility in its tube making capabilities and can easily respond to customer requirements for both sizes and quantities. QSIL has its own department of highly skilled glassblowers where the fused quartz materials are fabricated using both manual and machine assisted techniques to meet even the most demanding customer specifications. Focus is the manufacturing

of resized tubes up to an outer diameter of 1,000 mm and to a length of 5,000 mm.

With the acquisition of the technical ceramics expert Barat Ceramics, the QSIL Group strengthens its position as advanced materials specialist. Barat Ceramics offers its customers a wide range of modern high-performance oxide ceramic mate-rials of its own production. Parts made of technical ceramic are recommended for a wide range of applications due to their high wear resistance, hardness as well as corrosion and high-temperature resistance. Various system solutions made of metal-ceramic compounds are also part of the portfolio.

QSIL GmbH www.qsil.com Hall 10 / Booth B74


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NEWS Events

Ladle pouring system to maximize productivity

The North American foundry company EJ (headquarter in East Jordan, MI), known for municipal castings, is

successfully using the ladle pouring system Puma Pro from Induga in their new foundry since the end of 2018. The ladle pouring system was able to fit in a limited space and meet the needs of their high-volume production requirements.

From the beginning, the Puma Pro system demonstrated the ability to perform and meet the many variations of pouring programs EJ has in their portfolio. The modern pouring controller with control algorithm fills up the sprue cup quickly, accurately and repeatably. Based on weight information the controller stops the process at the right moment. This demonstrates not only the correct pour, but also provides substantially reduced waste (over-pour).

With thousands of moulds poured per year, this adds up to measurable cost savings.

The next pour will also be optimized by the iteratively learning controller, so that the level in the cup is controlled precisely, even when parameters like moisture of the sand, volume of the casting and other mould parameters are changing. The HMI monitor shows the operator what the controller is doing, so that he can see what the resultant pour will be. Via the programming capabilities of the system, the operator has everything under control even when there are numerous pattern changes per day.

The biggest disadvantage of any ladle pouring solution is the fact that during the ladle change, the machine cannot pour iron into the mould. This can be fully compensated by using the Induga Puma Pro 2 machine solution. Additio-nally, the machine can do other critical processes like pigging, deslagging and ladle change – safely, without reducing the production output of the castings.

By using the Induga 2 machine solution the foundry can use the full stop time of the pouring line for castings that require longer pouring times, without any loss in the process. The Induga Puma Pro 2 machine solution combines productivity and flexibility.

Induga GmbH & Co. KG www.induga.de Hall 10 / Booth H41

Low-formaldehyde system for cold box production

German foundries are faced with the challenge of redu-cing formaldehyde emissions in the exhaust gas flow of

their existing plants from 20 to 5 mg/m3 (mass concentration) by February 2020 at the latest. At GIFA 2019, ASK Chemicals will present a specially designed binder-additive-coating package that allows foundries to comply with this new limit value without investing in additional secondary measures.

The new concept reduces the formaldehyde emissions by more than 70 % and does not require investment in washers or RTO (i.e. regenerative thermal oxidation).

Analyses have shown that, in particular, the exhaust gas flow from coating drying furnaces plays a special role in the reduction of formaldehyde emissions. Cores produced in the cold box process have residual amounts of formalde-hyde per se, but can, in conjunction with an additive and coating, emit additional formaldehyde, especially at temperatures around 150 °C, so that the limit of 5 mg/m3 is easily exceeded.

The newly developed low-formaldehyde system (LFS) is a specially designed package of binder, additive and coating that, due to its design, develops only a very low basic-load and thus a greatly reduced formaldehyde poten-tial. Furthermore, the new system absorbs released form-aldehyde, so that the first users of this technology can undercut the 5 mg/m3 limit.

“With the application of the Ecocure Blue LFS binder, Miratec LFS coating and Veino LFS additive tailored to the specific requirements, the LF system meets the legal form-aldehyde limits with accuracy. This is a clear advantage for foundries that do not want to invest in secondary equip-ment at this time”, says Frank Lenzen, Technical Product Manager at ASK Chemicals.

ASK Chemicals GmbH www.ask-chemicals.com Hall 12 / Booth A22


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Developments in foundry lining technology

Foseco will highlight the latest developments in foundry lining technology at GIFA 2019. Including the latest

technology available for controlling metal flow in steel ladles and autopour iron applications.

The recent development of the Triad Z range brings added advantages in terms of superior slag resistance and enhanced hot properties of the castable system. Triad Z can be cast, pumped and shot-creted is now available for most of iron and steel foundry applications such as long campaign cupola melting, channel holding and pouring furnaces as well as iron and steel ladle applications.

Furthermore, a new generation of Kaltek board multi-life system has been introduced to the market to combine the Kaltek board properties (no pre-heating, metal cleanliness, insulation) with a Kaltek set that can be used up to five times and allow thermal cycles and nozzle exchange.

Foseco’s Alugard low-cement castables and Triad no-cement castable contain a new aluminium “non- wetting” additive giving excellent resistance to corundum development across a wider temperature band, while the dry-vibratable lining Kellundite is ideally suited to coreless induction melting furnaces.

Insural multi-part and highly insulating dosing furnace linings for aluminium foundries combine energy savings with long-service life and resistance to oxide build-up. Insural is a new multi-part and highly insulating lining which is delivered ready to install. Installation can be achieved in three days with no ongoing hydrogen issues and due to a totally dry installation process no sintering of the lining is necessary. Energy saving can be as high as 17 %.

On the stand Foseco will present a complete package of lining and purging refractories designed for long life and improved metal cleanliness in coreless induction furnaces melting steel grades. Foseco will also show a complete package of long-life linings for long campaign cupolas melting iron grades. The cupola portfolio consists of high quality Ramwell ramming mixes and Hydra-Max low cement castable lining systems enriched with silicon carbide and graphite aggregates to improve slag resistance.

The new Viso isopressed zoned nozzle offers the steel foundry a multi-life nozzle for improved productivity. The zoned nozzle uses a combination of different refractory systems to enhance strength and performance, thereby enabling repeated use of the nozzle in a steel foundry ladle.

Furthermore, Foseco will show the latest flow control technology for grey and ductile iron, especially for unheat-ed pouring boxes. Here, we will show a range of design and refractory combinations to meet the requirements of a variety of autopour applications.

The Ferrolab V thermal analysis system enable foundries to accurately monitor metallurgical process performance and take immediate corrective action by analysing base and final iron quality. Ferrolab V can be used on the melt deck to minimise variances in base iron by providing the operator information necessary to adjust the characteristics of iron within predetermined process specifications.

Vesuvius GmbH Foseco Foundry Division www.foseco.de Hall 12 / Booth A01/A02

Bionic design for charging racks reduces weight

A maximum loading capacity with a delicate structure – what nature shows us daily, is now also being used

in the casting design of high-temperature charging racks. Friedr. Lohmann GmbH Edelstahlgießerei has developed a bionic design which is a minor revolution in steel casting technology for heat treatment applications.

The Lilypad design is based on the supporting structure of an Amazon water lily and not only represents a milestone in steel casting technology due to its delicate design, but also sets new standards in terms of high-temperature resi lience. Pit furnace fixtures are preferably used for case- hardening and are subject to high thermal, mechanical and corrosive stresses at a process temperature of around 900 °C. This results in up to 25 % higher loading capacity at a given fixture weight.

Due to the thinner wall thicknesses, considerably less energy is required for heating – important impacts for CO2 reduction and capacity expansion without invest-ment costs or backfitting. The charging racks of Friedr. Lohmann GmbH Edelstahlgießerei are modular designed, so that no additional pattern costs are incurred, and the operator can choose between a large number of possible combinations for his specific application. All charging racks where the Machinery Directive applies are supplied with complete CE certification, operating manual and load diagrams.

Friedr. Lohmann GmbH www.lohmann-stahl.de Hall 9 / Booth E04


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NEWS Events

Updating the control systems in foundries

In times of increasing price pressure on foundries, it is important to exploit all potential for cost savings. The

Foundry Service spectrum for the modernization of con-trol systems includes all existing production facilities in foundries, such as LF/MF induction systems, heat treat-ment plants, moulding plants, mold transport systems, sand preparation systems, ladle transport systems, cooling water and filter systems, transport and dosing systems, production data recording systems and energy manage-ment systems.

The modernizations of the production plants are carried out by Foundry Service GmbH and is structured as follows: project planning of the switchgear, CAD design of electrical circuit diagrams, software development, dismantling of the old system, assembly of the new system, start-up and training.

The MeltingProcessor is a system consisting of hardware and software for controlling induction melting furnaces, which is suitable for retrofitting into existing furnace systems,

offering advantages over manual furnace operation such as reduction of the energy demand, increase of productivity by reducing non-productive time, reproducible quality of the melt, relief for the operating staff, increased opera-tional reliability, increased safety against, overheating of the refractory lining, special protection of the refractory lining e.g. through weight-dependent control of the power supply, documentation of operating data (ISO 9000ff). The following operating modes can be realized with the melt-ing processor: smelting, overheating, holding, cold start, sintering. In addition to the operating modes described above, the system also offers the following functions: logging of error messages, batch and shift logs, charge computation, analysis correction.

The heart of the charging system is a computer, which is located e.g. in the control station and which carries out a constant data exchange with a possibly existing Melting-Processor, the spectrometer, a central server in the com-pany network, the crane scale as well as one text display and one platform scale each for the addition of aggregates and alloys. The recipes for the materials to be produced are created on the charging computer and a sequence of recipes for a daily production is compiled. If desired, the recipe creation can also be carried out cost-optimized by the computer. The master data for the indicative analyses as well as the input materials and aggregates are the basis for recipe creation. Alternatively, the associated data (e.g. the percentage shares of the individual alloying elements) can be entered and managed on the computer itself or transferred from the server in the company network from any database system (SQL server, Oracle, etc.).

A program, which runs under Windows 98, 2000, NT and XP, is used for the convenient creation of factory test certificates according to EN 10204. The program automati-cally takes over the information required for creation, such as analysis data, mechanical properties, etc. from database files, into which the appropriate data are entered that are derived from other programs, such as MeltingProcessor, charging system, evaluation program for tensile specimens, etc. These files may be located on any computer within the company network.

Foundry Service GmbH www.foundry-service.de Hall 10 / Booth E20


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New generation of yellow flame detectors

From 22 July 2019, electrical and electronic equipment that was previously beyond the scope of Directive

2002/95/EC (RoHS1) will have to comply with Directive 2011/65/EU (RoHS2) on the restriction of the use of certain hazardous substances in electrical and electronic equip-ment. Siemens Building Products is now offering a new yellow flame detector that already complies with Directive 2011/65/EU for the supervision of yellow-burning oil flames in connection with the LMO, LMV2, LMV3, and LME7 burner controls. The QRB4 yellow flame detector is used for the supervision of oil flames in the visible range in connection with burner controls for oil burners in intermittent operation. It is functionally backward compatible and designed to replace the QRB1 and/or QRB3 flame detectors within the burner controls specified above either in new installations or even if spare parts are required.

The QRB4 is a compact flame detector (diameter 12 mm, length 68 mm) with an infused two-wire thermo-plastic cable. It is designed for frontal and lateral (90°) illumination. With its maximum spectral sensitivity of 540 nm, it offers optimal coverage of the maximum level of visible light radiation of yellow-burning oil flames. Cer-tain boiler parts can even give off a red light when the burner is switched off (e. g. a glowing boiler chamber wall). The QRB4 is less sensitive to red light in this regard, which ensures reliable operation since these glowing parts are not recognized as a flame. The intensity of the light radiation is controlled by measuring the detector

current through a photodiode. The flame detector can supply a stable current within an operating temperature range of -20 to +60 °C.

It is essential to ensure the appropriate polarity when connecting the flame detector; however, the flame detec-tor is protected against incorrect wiring and will therefore not be damaged beyond repair in the event of a polarity reversal. The housing features an IP54 rather than IP40 design to ensure even better protection of the flame detec-tor against dust and water. This safeguards the reliability of the flame detector for the duration of its service life. The QRB4 is available in various designs, including options with normal or high sensitivity, and with or without a flange/clamp or soft plastic plug. A guide groove in the securing flange and a cam on the detector clamp not only ensure secure and vibration-free mounting on the burner, but also make certain that the flame detector is correctly sited toward the flame if the flame detector is secured to the burner with a flange. The flange features 36 mm spacing. When fastening to the burner with a soft plastic plug, only a hole in the burner with a lateral groove is required. The sealing and securing ribs of the soft plastic plug hold the QRB4 firmly in the hole, while the guide spring guarantees correct alignment toward the flame.

Siemens AG Building Technologies www.siemens.com/buildingtechnologies-oem Hall 9 / Booth F41

Rekumat burner reduces atmosphere in the furnace chamber

The new Rekumat CR burner by WS Wärmeprozesstech-nik combines direct sub-stoichiometric heating with

indirect radiant tube heating, resulting in a reducing atmo-sphere within the furnace chamber and hereby minimizing oxidation of the heat treatment load.

The products of combustion are extracted from the furnace via the open-ended radiant tube in which they are completely oxidized. Heat generated thereby, is released into the furnace via the radiant tube. In a final step, the products of combustion pass over an integrated ceramic recuperator, preheating the combustion air.

This innovative design is a highly efficient and cost- effective alternative to atmosphere furnaces with the purpose of minimizing scale formation on steel and non- ferrous metals.

WS Wärmeprozesstechnik GmbH www.flox.com Hall 9 / Booth A76


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NEWS Events

Emission minimized with new radiant tubesESA has experience in V/H galvanizing and annealing lines, with U and M type radiant tubes using staged burners on one end and plug-in recuperators on the other. The company‘s inventions are zone virtualization by individual burner ratio control, pneumatic flow regulator to con-tinuously balance the volume changes of preheated air, to extend tube lifespan avoiding internal soot formation and

the off/min/max management to avoid thermal shocks on the radiant tube and reduce the fuel consumption.

ESA presents now the new developments of the plug-in recuperator (Patent Pending). Firstly, the new flue gas recirculation valve, where the staged injection of air into the RT burner already determines very low NOX levels, with the new adjustable FGR valve, it is possible to reach ultra-low NOX levels, by deciding the

flue gases volumes to be re-injected into the combustion air flow. During burner start-up, it limits the flue gas flow minimizing CO formation which is typical of that phase. After reaching working conditions, flue gas will recirculate regularly and safely to the burner.

Secondly, the new plug-in recuperator body. The pre-vious version used metallic bodies and tubes, requiring a great deal of welding. The new one is more efficient, using a fully casted body, easier and quicker to manufacture and assemble. Due to its inner lining, it is also thermally more efficient and safer for operators as it does not require any external insulation.

Thirdly, the new recuperator in SiC material. In addition to the standard version with metal finned elements, the new recuperator can adopt a silicon carbide recuperator. The working temperature is increased, and performance is comparable to the self-recuperative burners.

ESA S.p.Awww.esa-automation.com

Hall 9 / Stand D57

Control solution for multi-burner applications

Honeywell presents the next-generation Kromschröder BCU 4 Series, an all-in-one control solution for multi-

burner applications. Replacing an earlier product line, the BCU 4 Series 460, 465 and 480 models incorporate a range of refinements and new features designed for simplified enginee-ring, installation and start-up. They also provide various options to increase utility and effectiveness of the control solution – including a space-efficient design that allows the unit to be mounted close to a burner versus in a separate cabinet, enabling better system integration.

The BCU 4 Series offers industrial designers, engineers, operators and service technicians a multi-func-tional, modular control solution. It is designed for directly ignited or pilot/main burners of unlimited capacity in intermittent or continuous opera-tion, and for modulated or step-con-trolled gas burners. The BCU 4 Series was developed for furnace builder original equipment manufacturers (OEMs), burner manufacturers and end users in sectors such as metals, ceramics, food and automotive.

The three models in the series provide different func-tions. The BCU 460 model controls, ignites and monitors modulating or stage-controlled gas burners for intermittent or continuous operation, making it ideal for frequent cycling operations. The BCU 465 incorporates airflow monitoring and pre- and post-ventilation for use with recuperative burners. The BCU 480 can monitor pilot and main burners independently.

The BCU 4 Series comes equipped with an ignition transformer, burner control and an embedded human machine interface (HMI) – all arranged within compact housing. The four-digit display shows vital information such as program status, unit parameters and flame signals. All models possess a manual mode to adjust the burner and its diagnostics.

The control solution fulfils the requirements of the most important industry standards and has Industrial Internet of Things (IIoT)-ready Profibus, Profinet and EtherNet/IP network connections. These connections enable faster connectivity.

Honeywell Thermal Solutions www.honeywellprocess.com/hts Hall 9 / Booth D26


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Nitric oxide reduction in 3D printing

How can fuel and air be mixed so that the combustion process is modulated most effectively and as few

harmful emissions are generated as possible? Whole gene-rations of engineers have worked on this very question. Kueppers Solutions have now achieved a breakthrough in the domain of natural gas combustion: with its newly developed mixing unit, the gas exhaust can be adjusted so that far fewer nitric oxides are produced than with conventional mixing units. The component, made using metallic 3D printing, now enables nitric oxide emissions to be reduced by up to 90 %. Initial reference installations – equipped with the mixing unit, which uses several hund-red jets – are already successfully in use in a steel plant, a chemicals company and in the field of specialist plant construction.

How have Kueppers Solutions achieved this? Of course, not on their own, but rather in collaboration with several cooperation partners. They include the Institute for Com-bustion Technology at the RWTH in Aachen, the Gas- und Wärmeinstitut (Gas and Heating Institute) in Essen and the Ruhr-University Bochum. “Success cannot be achieved in isolation. You always need the right partner by your side”, says Managing Director Jens te Kaat. The right partners have also been brought on board for further market develop-ment: at the start of 2019, two regional supply companies

– Gelsenwasser and the Stadtwerke Bochum – joined forces with this SME company.

Kueppers Solutions GmbH www.kueppers-solutions.de Hall 9 / Booth E60

New packaged burner system for heating processes

MSB Packaged Burner is a complete system which includes burner, gas train, fan and control panel. Fuel/

Air Ratio Control can be achieved by using pressure balance regulator or electronical linkage. Due to the custo mer requests, oxygen trim system can be added. The system is entirely designed suitable for EN 746 - 2 combustion safety regulations.

MSB Burners are supplied between 50 and 5,000 kW and with three different flame tubes. Metal Flame Tube (Max. Temperature: 1,100 °C), SiC Flame Tube (Max. Temperature: 1,350 °C), and Refractory Tile (Max. Temperature: 1,600 °C).

MSB Burner provides wide combustion range. It is suitable for excess air operation. It can operate with both λ = 0.7 and λ = 40. Installation can easily be done with the help of pressure-capacity curves which are generated after the performance tests that are made in Yeten ‘s test furnaces.

Application areas include dry-off and curing furnaces, rotary furnaces, air heaters, incinerators, paper and textile drying facilities, food industry, baking furnaces, painting facilities, annealing and aging furnaces.

Yeten Combustion & Energy Ltd. www.yeten.com Hall 9 / Booth D75


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