WE TREAT WITH HEAT. Eisenmann Thermal Solutions

Transcription

1 WE TREAT WITH HEAT Eisenmann Thermal Solutions

2 03 Eisenmann Thermal Solutions André Görnhardt, Managing Director Thermal Solutions for every challenge. To stand still is to fall behind this saying is truer than ever. And Eisenmann has always been exceptionally forward-looking for our customers and with our customers. But we also wish to briefly take stock by looking back at Ruhstrat s 127-year history as a manufacturer of industrial ovens. We are combining two businesses with complementary skills and portfolios to create Eisenmann Thermal Solutions greatly enhancing our value as a partner to our customers. Our experts develop sophisticated thermal processing technologies that produce lightweight and highperformance materials with exactly the properties required. Eisenmann systems are suitable for a variety of thermal processes in the 100 C to 3,000 C range. In addition to ensuring ideal conditions in our ovens and furnaces, we also integrate them seamlessly into the wider production process. We can also design energy-efficient powersupply systems for our ovens and furnaces, and ensure their operational reliability, by leveraging the online voltage regulation and optimization devices we make ourselves. Moreover, customers can develop and test thermal processes for new products at our Technology Center, in collaboration with our engineers. Together, they can also improve existing processes with the aid of simulations, for example. With a broad portfolio and global reach, Eisenmann Thermal Solutions is a one-stop source of highly innovative, highly efficient solutions. We look forward to helping you address your current and future challenges as your preferred technology partner. Our evolution so far 1894 Development of the electrical slide resistor First resistance-heated high-temperature furnace with its own specially designed transformers Adolf und Ernst Ruhstrat establish an electrical business in Göttingen 1916 First emergency lighting system with individual batteries Expansion of the business line for transformers, power resistors and resistance-heated furnaces Eugen Eisenmann engineering business in Stuttgart First product: a lumber-drying kiln 1951 Headquarters relocated to Böblingen Relocation to Bovenden near Göttingen Acquisition of US furnace manufacturer Temtec Allied First carbonization furnace for carbon fiber Development of an enameling oven 1989 First sintering oven for ceramics New Ruhstrat headquarters built in Bovenden First oxidation oven for carbon fiber 2005 Ruhstrat amalgamates with Eisenmann s Process and High Temperature Technology business unit to First fully automated roller- r form Eisenmann Thermal Solutions type kiln for heat-treating 2015 aluminum wheels 1997 Eisenmann acquires Ruhstrat 2011 Eisenmann Thermal Solutions»

3 The passion that drives us. 05 Eisenmann Thermal Solutions Interdisciplinary teams of highly motivated specialists develop made-to-measure systems in close collaboration with the customer. A DISCUSSION WITH SIMON SCHURR AND WILLI MEYER Simon Schurr, Sales Manager, Advanced Ceramics I m a customer account manager and part of an interdisciplinary team that designs and develops hightemperature furnaces for technical ceramics. Our teams are comprised of highly motivated specialists who are passionate about what they do. We share a fascination for technical details, and strive to be the very best development partner to the customer we can be. We always aim to design the best possible system in terms of technology and cost-efficiency, and to this end, we work closely with the customer at every stage. The customer s focus is the yields and quality achievable within a given budget or defined energy input. We rigorously apply our broad skillset to every aspect of the end-to-end process and create a solution that delivers maximum reliability, safety, eco-friendliness and flexibility. Often, the result is a highly efficient production line or an oven upgrade that cuts energy consumption. To my mind, one of our main strengths is that we not only develop a production process, but also manage the transition from lab to factory. With the help of flow simulations and experiments at our Technology Center at our headquarter in Bovenden, we scale the customer product and the associated treatment process. Willi Meyer, Senior Expert Every system is made-to-measure the end-result of more than a hundred years engineering experience. We assume responsibility for all aspects of the process, from the first rough sketch to on-site installation and commissioning. We involve sales, maintenance and service people from day one. I offer advice on technical issues such as throughput, materials, and temperature, and whether a nitrogen or a hydrogen atmosphere is appropriate. I explore all of the options with our development engineers to determine the best solution. We perform tests at our Technology Center at all stages of development to identify quickly where action is needed in close collaboration with our customers. As a result, we can work more efficiently, and deliver the systems required all the sooner, without sacrificing quality.

4 We treat with heat... Made-to-measure solutions. 07 Eisenmann Thermal Solutions Our engineers are committed to providing you with made-to-measure thermal processing solutions. Our specialists analyze your requirements and develop high-quality systems that will serve you well today and in the future. You can depend on the expertise of our skilled employees, and on our immense handson experience as an oven manufacturer. Whatever your challenge, we can deliver the best-fit solution. OUR PORTFOLIO INCLUDES THE FOLLOWING TREATMENTS LIGHTWEIGHT MATERIALS TECHNICAL CERAMICS SOLUTIONIZING AGING HARDENING ANNEALING TEMPERING BRAZING NITRIDING CARBURIZING CARBONITRIDING DEBINDING CARBON BURNOUT BISCUIT FIRING CALCINATION REDUCTION HIGH-TEMPERATURE CLEANING SINTERING OXIDATION PYROLYSIS CARBONIZATION GRAPHITIZATION SILICONIZING HYDROGEN SINTERING VACUUM SINTERING BRUSHING DEGREASING ETCHING PICKLING CONVERSION TREATMENT HEAT TREATMENT OF ALUMINUM AND NON-FERROUS METALS PRESS HARDENING OF STEEL OXIDATION AND CARBONIZATION OF CARBON FIBER SURFACE TREATMENT OF ALUMINUM COIL DEBINDING AND SINTERING OF ELECTROCERAMICS, FILTERS AND MEMBRANES HIGH-PERFORMANCE CERAMICS NEW MATERIALS THERMAL PROCESSING OF HIGH-PERFORMANCE GRAPHITE, NANOMATERIALS AND COMPOSITES ENAMELING POWDER CHEMICALS AND CATALYSTS ELECTRICAL SOLUTIONS METAL POWDERS, CATALYST MATERIALS, AND MATERIALS FOR BATTERIES ELECTRICAL TESTING SYSTEMS VOLTAGE OPTIMIZATION HIGH-PERFORMANCE METALS ELECTRICAL COMPONENTS HARDENING OF METAL SAW AND RAZOR BLADES TRANSFORMERS AND CHOKES SINTERING OF METAL POWDERS AND INJECTION-MOLDED METAL COMPONENTS POWER RESISTORS ENAMELING

5 09 Eisenmann Thermal Solutions 1,800 C 1,800 up to 3,000 C Graphitization up to Sintering ceramics up to up to 500 C Aluminum heat treatment Keeping you safe and sound. 1,400 C Metal sintering and hardening WE CAN HANDLE ANY TEMPERATURE SAFELY AND RELIABLY Flammable gases may be released or toxic substances produced as part of the conversion process that takes place inside industrial ovens. As a result, this equipment can be hazardous to health and the environment. The dangers are many and various, and they are frequently underestimated. But we at Eisenmann never leave employee safety to chance: for us, certification of a production system starts as soon as you place your order and continues throughout the life-span of the equipment.

6 OLIVER deals with dips and surges. 11 Eisenmann Thermal Solutions Production plants are critically dependent on a uniform, reliable supply of electricity. But the mains voltage can experience dips and surges at any time for example when large electric loads are switched on or off. Power-supply fluctuations can interrupt production and cause costly downtime. In response to this threat to operations, Eisenmann Thermal Solutions has developed OLIVER, short for Online Voltage Regulation System. OLIVER reliably compensates for over- and undervoltages of up to 40 percent. If the mains voltage decreases by more than ten percent, sensitive powersupply components can enter an undefined state even if the drop only lasts a few milliseconds. OLIVER stabilizes the power supply extremely quickly, and can be easily integrated into the customer s production environment. To protect sensitive equipment, the online regulation system is connected in series between the low-voltage distribution system and the load. Unlike UPS (uninterruptible power supply) systems, OLIVER does not significantly affect the short-circuit power. Existing protection devices, such as fuses and circuit breakers, can continue to be used. OLIVER is largely maintenance-free and consists of components such as rectifiers, inverters, transformers and bypass switches. It requires no internal energy storage in the form of batteries, and no cooling. In terms of cost, OLIVER is a third of the cost of an equivalent UPS system. On request, Eisenmann Thermal Solutions can perform tests to determine the stability of the power supply. At present, OLIVER is available with a power rating of 300 kva; versions with other power ratings in the 60 to 2,000 kva range are under development. Undervoltages in the power supply caused by lightning or short-circuits in the distribution network, for example impact operations in production plants. Andreas Möbus, head of the Electrical Technology business segment Causes of voltage drops in the mains supply Short-circuits in the supply grid Lightning strikes High loads and significant changes in load Switching operations at the utility Power stations going on- and offline Fluctuating power sources (wind and solar) Birds and bird droppings Direct impact Utility s circuit breaker trips (typical response time ms) Local events have a knock-on effect throughout the grid Fuses and relays drop out Sensors detect incorrect values Frequency inverters drop out Consequences Production comes to a standstill Production quality standards are not met The manufacturer suffers financial losses You are an electrical engineer and manage the corresponding unit at Eisenmannn Thermal Solutions. How do your team s skills help create solutions tailored to customers real-world needs? We supply electric industrial ovens to customers worldwide. And we are aware that unstable mains voltage is a problem in many regions. Our complex systems can only guarantee highly consistent thermal processes if the power supply is stable. So our ability to offer voltage regulation systems with our industrial ovens is key for our customers. It also means we provide truly end-toend solutions. What other technologies in addition to OLIVER deliver lasting benefits for production-system operators? The Electrical Technology business segment develops products for voltage stabilization and electrical testing, transformers, chokes and power resistors. Our electric industrial ovens require transformers to be used in the voltage supply systems. That s why we primarily develop and manufacture thyristor-controlled transformers to control the temperature in the ovens heating zones. But our transformer portfolio also includes models with up to 20 MVA rated power and up to 36 kv rated voltage. These can be employed in power-supply solutions for entire production systems.

7 Solutions for global market leaders. 13 Eisenmann Thermal Solutions AUMINIUM WHEELS FROM BORBET AND RONAL Alloy wheels are among the most common special features chosen for new cars. In addition to their aesthetic appeal, aluminum wheels weigh up to five kilograms less than conventional steel rims. This improves the car s acceleration, steering and fuel efficiency. Eisenmann collaborates closely with two of the world s leading aluminum wheel manufacturers. The first is family-run Borbet a company synonymous with quality, innovation and pioneering design. They have already contracted Eisenmann to supply 20 heat treatment systems at manufacturing facilities in Europe and the US. The most recent project is for a new factory in Germany. WHY EISENMANN? Committed to long-term collaboration A dependable partner High-quality processes and products Technology made in Germany The second is Swiss-based Ronal Group, famous for leading-edge technology, creative design and uncompromising quality. It leverages Eisenmann heat treatment systems to guarantee its high standards. Its superior engineering and extensive experience have made Eisenmann a key partner to manufacturers of aluminum wheels. Its solutions ensure strict compliance with defined temperature profiles, and a uniform, reproducible quenching process producing aluminum wheels whose strengths lie within a narrow range. Eisenmann provides us with energy-efficient solutions entirely designed and built in-house. EXHAUST-GAS SENSORS MADE IN EISENMANN KILNS: ADDITIONAL CAPACITY FOR BOSCH Bosch is a leading developer and manufacturer of lambda sensors which are made from high-quality materials using innovative production processes. Lambda sensors from Bosch have a long life expectancy, offer maximum resistance to thermal shock and breakage, and are tailored to the corresponding engine types. To keep product quality consistently high, the fabrication method must yield materials with exactly the right properties. WHY EISENMANN? Energy-efficient thermal process An integrated, end-to-end solution To this end, Bosch has deployed Eisenmann kilns for many years. These systems boast significantly reduced energy consumption, as the hot exhaust gas from the thermal oxidizers is re-used to purify the process air. Eisenmann provides us with energy-efficient solutions entirely designed and built in-house. They supply high-temperature kilns and conveyor systems tailored to our needs, explains the project leader and engineer responsible for the sensor manufacturing process at Bosch s Bamberg plant. Peter Borbet, founder and managing director of the Borbet Group.

8 15 Eisenmann Thermal Solutions FINISHED IN THE FURNACE Wüsthof, a German manufacturer with a long tradition, produces more than 1.7 million forged knives a year. Each one undergoes more than 40 process steps to meet extremely high quality standards. Wüsthof s premium products are exported worldwide. And for more than a decade, it has tempered its knife blanks with fully automated Eisenmann furnaces. We have seamlessly integrated the blank hardening and annealing system with the wider production process from loading to final cooling. After the blanks have been forged and laser-cut, they are heated to around 1,050 C in the hardening furnace and then quenched to permanently retain their shape. The knives are then heated again to 180 C in the annealing furnace to obtain the ideal properties they need to be strong yet flexible. The state-of-the-art, fully automatic production system handles up to 330 kilos of material every hour. WHY EISENMANN? Fully automated furnace An integrated, end-to-end solution We re flying high with carbon. Wüsthof quality at the cutting edge. CARBON FIBER THE COMPOSITE MATERIAL OF THE FUTURE Lightweight yet extremely strong, carbon fiber is seen by many as the standout material of the 21st century. Demand for carbon fiber is growing fast across many industries, from automotive and aerospace to construction and power generation. Eisenmann is a trusted partner to leading carbon fiber manufacturers world-wide. No other provider can supply truly end-to-end carbonization systems. In concrete terms, Eisenmann develops and builds oxidation ovens, carbonization ovens, and exhaust-air purification systems with integrated heat recovery. Its engineers draw on their vast knowledge and experience to develop thermal processing systems that are geared to customer-specific needs. Collaborating closing with the customer, they define and integrate the interfaces at all stages of manufacturing, generate synergy, and drive down costs.

9 Eisenmann Thermal Solutions GmbH & Co. KG, Leinetal, Bovenden, Germany, Phone: , Fax: Eisenmann Thermal Solutions GmbH & Co. KG I I 01 All rights reserved. All text, images, photos and graphics are subject to copyright and other intellectual property laws. Content may only be used with the express permission of Eisenmann Thermal Solutions GmbH & Co. KG. All content, including, without limitation, specifications, descriptions and illustrations, are subject to error and change, in particular with regard to ongoing development of our products in line with technological progress. Changes to content will not be proactively communicated. Technical specifications may vary from country to country. ETS-B-001a-en-1015