News
Technology
May 2014
38
Wire Körner has launched a new series
of directly heated patenting furnaces
fitted with automatic furnace atmosphere
control and burner with heat recuperation.
With these new energy-saving furnaces,
the company is further expanding its range
of efficient and eco-friendly heat treatment
plants for wire.
Based on his good experience with the
furnace, a German customer has already
ordered an extension to his existing
unit. The first unit of this new furnace
generation has been in operation for two
years. Designed for a throughput of 2,000t
per hour, it processes wire in diameters
from 1.5 to 5.5mm. The plant expansion
was expected to be commissioned in April
2014.
By implementing a wide array of
innovative features, Wire Körner has
increased the efficiency of patenting
furnaces for wire and achieved savings
on energy consumption of some eight to
ten per cent compared to conventional
furnaces. The very first furnace of this new
generation has already been in production
for more than two years.
With an innovative sensor, Wire Körner
has realised a system for controlling the
furnace atmosphere. Via the furnace
control system the air/combustion gas
ratio is set exactly within a specified range.
The high control precision and stability of
the gas/air ratio makes the new furnaces
superior to pre mix systems. In addition to
the savings on energy, controlling the air/
gas ratio keeps NOx emissions low and
prevents decarburisation of the wire. The
furnace temperature is adjusted with a
precision of ± 2°C.
A central recuperator installed in the waste
gas duct preheats the combustion air for
the high-speed burners to 200-250°C,
while reducing the waste gas temperature
at the stack from 600°C to 400-500°C.
Already in the preheating zone Wire
Körner exploits the thermal energy of the
waste gas to heat up the wire entering the
furnace. This reduces the energy demand
for preheating.
In contrast to previously used burners, the
high-speed burners employed by Wire
Körner can be adjusted in several steps.
This ensures that the burners consume
exactly the amount of energy they need,
not more.
The company has brought down heat losses
via the furnace wall by optimising the layout
of the wall, by insulating ceramic fibres. An
additional coating ensures a long service life
of the furnace wall even under conditions of
high CO contents and high flow velocities.
An additional, 2.5-cm-thick Microtherm®
insulating layer behind the refractory brick
lining brings down heat losses even further.
The furnace is directly heated. The heat is
transferred into the wire by convection,
at flow velocities of up to 120m/s. This
provides much better energy efficiency
than heating by radiation.
Wire Körner GmbH – Germany
Website
:
Offering high efficiency and economic lubricants
has always been a great challenge for wire
drawing lubricant manufacturers.
French company Condat answers this problem
with its widely approved aluminium and
aluminium alloy drawing oil, Vicafil TFH 1167,
which was launched at wire 2014 in Düsseldorf,
Germany, in April.
This oil-based lubricant was developed with
a primary objective of providing the best
performance to preserve dies and draw high
quality wires; but without compromising
simplicity of use and long service life.
Vicafil TFH 1167:
•
uses a low viscosity base oil in order to
improve cooling but reduce consumption by
minimising the amount of residue on drawn
wire
•
includes a package of additives to limit the
production of sludge, thus reducing machine
maintenance and extending lubricant life.
No additives are required during the whole
product life. Using Vicafil TFH 1167 affords
reduced bath maintenance costs, and thanks to
its properties, it suits most drawing operations
and diameters from 0.8mm to rod break drawn.
Moreover, it can be used in either immersed
or sprayed type drawing machines, without
damaging equipment.
Condat – France
Website
:
Aluminium drawing with Vicafil TFH 1167
▲
▲
Aluminium drawing oil Vicafil TFH
1167 from Condat
New series of directly heated furnaces
Sikora continues its product offensive for quality assurance
in drawing towers with the new fibre lump 6003 micro. This
sets a quality statement in the fast growing fibre market. The
new lump detector detects faults on the fibre surface 100
per cent continuously during the drawing process at a speed
of up to 3,000m/min.
This performance is achieved by the use of six measuring
axes. Shadow areas are eliminated and even the smallest
faults of a height from 5µm are detected. The length of detectable faults is 50µm.
In combination with a double sensor technology, punctual non-conformities are
detected.
The fibre lump 6003 micro is designed for product diameters from 100 to 500µm.
The device can easily be integrated into new or existing drawing towers, and can be
connected to both the Sikora display and control system fibre ecocontrol or to a line
computer. In addition to the installation in drawing towers, the fibre lump 6003 micro
is suitable for colouring lines.
Sikora AG – Germany
Website
:
Quality offensive continues
▲
▲
The new fibre lump 6003
micro from Sikora
▲
▲
Wire Körner is expanding its range of furnaces
