Process Optimization Workshop

Transcription

1 Process Optimization Workshop Log Equipment Panel Alessandro Guerrini, Turla Carsten Dede, OMAV David Jenista, Granco Clark David Turnipseed, Belco Industries Chicago, Illinois October 25-26, 2016 Moderator: Mark Butterfield, Magnode

2 Q #1 (1 of 3) Alessandro: What types of systems are there for storing and moving billets and logs, and for selecting the lengths and alloys desired to be fed into the furnace next? - Different alloys in every slot - Possibility to track cast and serial number of logs - Tracking of extrusion Photo Courtesy of Turla

3 Q #1 (2 of 3) Alessandro: What types of systems are there for storing and moving billets and logs, and for selecting the lengths and alloys desired to be fed into the furnace next? - Different alloys in every slot - Possibility to track cast and serial number of logs - Tracking of extrusion Photo Courtesy of Turla

4 Q #1 (3 of 3) Alessandro: What types of systems are there for storing and moving billets and logs, and for selecting the lengths and alloys desired to be fed into the furnace next? - Different alloys in every storey - Possibility to track cast number of logs - Tracking of extrusion Photo Courtesy of Turla

5 Q #2 David J: Does equipment require logs straighter than casting specifications? Photo Courtesy of Granco Clark

6 Q #3 David J: Do many extruders still utilize pre cut billet? Photo Courtesy of Granco Clark

7 Q# 4 Carsten : Do you have any thoughts about induction furnaces for the NA mkt? Can you share the Pros & Cons? Photo Courtesy of OMAV

8 Q# 5 (1 of 2) - Alessandro: What have been some of the improvements in gas heating systems that have boosted energy efficiency? Efficiency : 81% Photo Courtesy of Turla

9 Q# 5 (2 of 2) Carsten: What have been some of the improvements in gas heating systems that have boosted energy efficiency? Chart Courtesy of OMAV

10 Q #6 (1 of 2) Alessandro: What have been some of the improvements that have reduced maintenance requirements and costs? STeP5 burners Photo Courtesy of Turla

11 Q# 6 (2 of 2) Carsten: What have been some of the improvements that have reduced maintenance requirements and costs? Photo Courtesy of OMAV

12 Q# 7 (1 of 2) Alessandro : What are the trends that you are seeing in log/billet preheating? - Preheating through exhaust fumes (5 energy recuperations steps) - Convection heating in direct zones - Indirect heating zone - Pre-heating tunnel Photo Courtesy of Turla

13 Q# 7 (2 of 2) Carsten: What are the trends that you are seeing in log/billet preheating? Photo Courtesy of OMAV

14 Q # 8 David T: What are the pros and cons of different ways to move logs and billets through gas fired furnaces? Log/Billet Pusher Log Furnace Entrance Billet Furnace (Door Open) Furnaces are closed up better with Log/Billet Pusher and Gravity Roller design to reduce outside cooler ambient air from entering and improved pressure control. Photos Courtesy of Belco Industries (Door Closed)

15 Q# 9 (1 of 3) David T: Have there been any technological changes in thermocouple designs which can improve accuracy & reliability and reduce maintenance requirements? Thermocouple Probe Unit Maintenance Understanding the function of each part of the T/C probe assembly is critical to performing good maintenance and achieving reliable and accurate temperature readings. The Type K two rod T/C probe assembly is a proven design that works well if properly maintained. Photo Courtesy of Belco Industries

16 Q# 9 (2 of 3) Carsten: Have there been any technological changes in thermocouple designs which can improve accuracy & reliability and reduce maintenance requirements? HP7 VERTICAL THERMOCOUPLE Double thermocouples driven by pneumatic cylinder with tilting pneumatic actuated door, cooling with air. SLIDING door type to eliminate any contact and pressure on the refractory crown and to avoid any wearing. The thermocouple is completely closed in an air cooled housing mounted on the top of the sliding door. Photo Courtesy of OMAV

17 Q #9 (3 of 3) Alessandro: Have there been any technological changes in thermocouple designs which can improve accuracy & reliability and reduce maintenance requirements? Thermocouple set-up - Vertical - Water cooled - Fast plug in Photo Courtesy of Turla

18 Q# 10 Carsten: What are the tradeoffs between log saws and shears? (chips, quality of cut ends/deformation, ) Video Courtesy of OMAV

19 Q# 11 Carsten: What are the recent trends in how European extruders are thinking about log shears -vs- log saws? Photo Courtesy of OMAV

20 Q# 12 David J: How can a cold saw be incorporated into a system? Can one saw handle multiple presses? Different diameters? Photo Courtesy of Granco Clark

21 Q# 13 (1 of 3) David T: Are there developments that have reduced kerf? Reduced Saw Blade Kerf The Narrow Cut Hot Log Saw may save as much as $89,700 a year over a single blade Hot Log Saw. This figure is based on a production rate of 120,000 cuts per year on a 9 diameter log and at a cost of $0.75 per pound. Photos Courtesy of B&O Saws

22 Q# 13 (2 of 3) David T: Are there developments that have reduced kerf? Reduced Saw Blade Kerf Standard Single Blade Saw Standard Blade Size for 9 Diameter Logs Blade Diameter: 28 in. Kerf Width: 1/4 (.240 in.) Al. Chip Weight: lb./cut Swarf Weight per 1000 Billets Cut: 1,543 lbs. Scrap Photo Courtesy of Belco Industries

23 Q# 13 (3 of 3) David T: Are there developments that have reduced kerf? Reduced Saw Blade Kerf Dual Blade Saw Standard Blade Size for 9 Diameter Logs Blade Diameter: 18 in. Kerf Width: 1/8 (.125 in.) Al. Chip Weight: lb./cut Swarf Weight per 1000 Billets Cut: 771 lbs. Scrap 50% Reduction Photo Courtesy of Belco Industries

24 Q# 14 Alessandro: Please describe how a log optimization system works, to minimize log end scrap Log Optimization - Different cycles can be stored in the recipe - Two pieces billets deliverable at every log change - Applicable to log saws and shears Photo Courtesy of Turla

25 Q# 15 David J: I've heard about different systems for joining the end piece of one log to a piece from the next - what systems are there? Photo Courtesy of Granco Clark

26 Q# 16 (1 of 2) David J: We all know that the extrusions generally get hotter as more of the billet is extruded. Are there systems in the gas fired or induction furnaces to help combat this? Photo Courtesy of Granco Clark

27 Q# 16 (2 of 2) Alessandro: We all know that the extrusions generally get hotter as more of the billet is extruded. Are there systems in the gas fired or induction furnaces to help combat this? Photo Courtesy of Turla

28 Q# 17 David J: What is meant by a "taper quenching" system and where should it be used? Photo Courtesy of Granco Clark

29 Q# 18 (1 of 2) David J: Please briefly describe the different types of ways to move billets from the furnace to the press. Photo Courtesy of Granco Clark

30 Q# 18 (2 of 2) David J: Please briefly describe the different types of ways to move billets from the furnace to the press. Photo Courtesy of Granco Clark

31 Q# 19 (1 of 2) David T: Are there new developments in delivering the billet(s) from the furnace to the press? Billet Loading with Linear Loader Rear Loading, Shifting Stem, Short Stroke Video Courtesy of Belco Industries

32 Q# 19 (2 of 2) David T: Are there new developments in delivering the billet(s) from the furnace to the press? Billet Loading with Linear Loader Rear Loading, Long Stroke Videos Courtesy of Belco Industries

33 Q# 20 Alessandro: Please describe how billet can be lubricated before press Billet lubrication - Before the press - On dummy - On shear blade Video Courtesy of Turla Photo Courtesy of Granco Clark

34 ATTENDEE QUESTIONS