PWHT
PWHT
PWHT
Presented By
Arvind C. Thekdi - E3M, Inc.
Arvind Thekdi - E3M, Inc.
Sales
Heat Treating Industry, Processes and Equipment
Presentation Content
• Where Is It Used?
Holding
(soak)
ng
a ti
Temperature
He
Co
oli
ng
Time
• Aircraft Industry
• Automobile Manufacturing
• Defense Sector
• Forging
• Foundry
• Heavy Machinery
Manufacturing
• Powder Metal Industries
SIC Industry
331 Steel Mills
332 Iron and Steel Foundries
34 Metal Fabrication
Machinery and
35 & 36
Electrical/Electronic Equipment
37 Transportation Equipment
3398 Commercial Heat Treating
5051 Steel Service Centers
• Ferrous Metals
– Steel
– Cast Iron
– Alloys
– Stainless Steel
– Tool Steel
• Non-ferrous Metals
– Aluminum
– Copper
– Brass
– Titanium
• Loading
• Cleaning
• Heating
• Pre-wash with coalescer • Preheating
• De-phosphate system • Heating
• Spray rinse • Soak & diffusion
• Pre-cooling
•
Unloading
Arvind Thekdi - E3M, Inc.
Sales
Commonly Used Equipment
for Heat Treating Operations
Induction Equipment
Cont. stripline
Conveyor
4395 Pusher
6000
Car Bottom
Pusher Fluidized bed
Salt-bath
3195
4890 Rotary hearth, shaker hearth
Conveyor
50 Bell, hood, tip-up
Plasma
330 4765
5 130 Vertical Pit Induction
55
Laser
2510
Electric beam
Vacuum
Flame heads
Sales
Heat Treating Furnaces
Two Primary Types
• Atmospheric
– Operated at ambient (atmosphere) pressure.
– Load is heated and cooled in presence of air or
special gases (process atmospheres), in liquid
baths or in a fluidized bed.
• Vacuum
– Operated at vacuum or sub-atmospheric pressure.
– May involve high pressure gas cooling using
special gases.
– Includes ion or plasma processing equipment.
Burners
* These could be directly exposed to the work
or can be outside a muffler a retort.
Direct fired muffle furnace
Types of Furnaces
· Coil/foil Annealing Furnaces
· Rod/wire Annealing Furnaces
· Log Homogenizing Furnaces
· Ingot Preheating Furnaces
· Aging Furnaces
· Indirect Heating
(Radiant Tubes or Electrical Resistance)
• Protective
– To Protect Metal Parts From Oxidation or Loss of Carbon
and Other Elements From the Metal Surfaces.
• Reactive
– To Add Non-metallic (i.e., Carbon, Oxygen, Nitrogen) or
Metallic (i.e., Chromium, Boron, Vanadium) Elements to
the Base Metal.
• Purging
– To Remove Air or Flammable Gases From Furnaces
or Vessels.
Or:
• Mixture of Commercial Gases
(N2, H2 and Hydrocarbons)
• “100 %” Efficient
Disadvantages - Drawbacks
• Better Temperature Uniformity and
Controllability • Higher Operating Cost : 2 to 3 Times for
Major Issues and Concerns
• Can Be Used for Higher Temperature Heat Treating Furnace Applications
• Capital and Operating Cost
Processes • Heating Elements Burn-out, Short Life and
• Safe - No Explosion Hazards Expensive to Replace • Product Loss
• No Flue Gases to Deal With • Danger of Elements Shorting Due to
Possibilities of Metal Parts Drop • Environmental, Safety and
• No Pollution or Emissions of NOx Etc. • May Need Expenses for Substation, Health
• Lower Initial Cost for Furnace Transformer Etc.
• • Corrosion, Soot Deposits Etc. For • Productivity and Quality
Easy to Install and Operate
Applications With Process Atmosphere
• Can Be Easily Automated • Other factors
• Longer Furnace Length for the Same Heat
Input, Particularly for Continuous Furnace
Arvind Thekdi - E3M, Inc.
Sales
Electrical Heating Terms and Cost
• “100 %” Efficient
• Better Temperature Uniformity and Controllability
• Can Be Used for Higher Temperature Processes
• Safe - No Explosion Hazards
• No Flue Gases to Deal With
• No Pollution or Emissions of NOx Etc.
• Lower Initial Cost for Furnace
• Easy to Install and Operate
• Can Be Easily Automated
• Induction Heating
• Heating Elements
• Power Supply
• Power Control System Connected with
the Furnace Temperature Control
System
• Water Cooling System
Notice:
• Electric heating elements connections
• Lack of burners, vents, air-gas piping or flue gas vents or ducts
Negative: Positive:
• Higher Capital Cost • Process Repeatability
• Higher Utility • Temperature Uniformity
(Electricity) Cost • Reliability of Operations
• Higher Overall • Better Operating Environment
Operating Cost • No or Low Environmental
• Lower Overall (Perceived Emission) Problems
Capacity • Automation - Better Application
• Less Flexibility for Computer Control
www.gasfiredvacuum.com
Thanks for
These Tools Showing Us
will help you How!
Prosper! Understanding IS
the Key to
Obtain Results!
*Content
Arvind Thekdi -Partially
E3M, Inc.Provided Through Dominion Participation in both the Energy Solutions
Sales Center’s Heat Treat Awareness Consortium and the DOE BestPractices Program
How to Use These Tools and Models
1. Discuss the fundamental cost differences between natural gas and
electricity with customers. Electric cost is usually 3 to 5 times the gas
cost on the basis of the total BTU’s supplied to the process equipment.
2. For most plants, a relatively small number of all installed process
equipment usually consume the largest amount of energy. Identify the
top-users and gather basic information on energy use for all major
energy use equipment in the plant.
3. For major energy using equipment, record name-plate data and analyze
how and when energy is used. Then, estimate the efficiency of the
process based on age of existing equipment (older is lower efficiency
generally), actual data, referencing the charts included in these Tools
and Models or by contacting the original equipment supplier.
4. The operation cost comparison for selected equipment can be completed
by entering efficiency and energy cost information in the Cost
Comparison Calculator Model cells OR by reading the general
results, in certain cases, from the charts (see pg’s 4 & 5).
Cost Comparison Factors affecting energy cost include 1) Efficiency of gas and electrically
heated furnaces 2) Cost of gas and electricity and 3) Number of hours
for Gas Compared
equipment is operated.
Arvind Thekdi - E3M,
to Electrical Inc.
Heat
Sales
Factors affecting efficiency of gas-fired equipment
1. Flue (exhaust) gas temperature
2. Oxygen (or CO2) in flue gases
3. Combustion air temperature (to the burner)
4. Oxygen injection or enrichment (if any) in the incoming
combustion air
35.00
30.00 Electrical Equipm ent Efficiency - 60%
Gas Cost $/MM Btu
25.00 75%
20.00
15.00
85%
10.00
5.00
0.00
3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
Electricity Cost Cents/kW
8.0
E lectricity C o st C en ts/kW
5.0 60%
4.0
3.0 80%
2.0
1.0
0.0
5.00 6.00 7.00 8.00 9.00 10.00 11.00
Gas Cost $/Million Btu
80
70
60
50
40
30
600 800 1,000 1,200 1,400 1,600 1,800 2,000
Exhaust Flue Gas Temperature (Deg. F)
Note:
Gas equipment provides savings when gas After Entering Gas
cost is equal to (or below) this gas cost
$ 30.31
Combustion Data, Input
the Current Power Cost
to Determine the Gas
Cost Point that Provides
Power Cost (Cents/kWh), enter in 0.045 Savings
0.045
format
Combustion
Furnace Flue Gas Oxygen in Flue
Excess Air Air Available Heat
Temperature Gases
Temperature
% of gross
Deg. F. % % Deg. F.
Heating Value
Modified
1,400 2.1 10.2 500 66.17
Case
Note:
To Enter Data, “Double-
Gas equipment provides savings when gas cost Click” on the Green
is equal to (or below) this gas cost
$ 19.93 portion of the table cell.
Then “Click” again in
the cell until the curser
appears and make
desired entry. Finally,
Power Cost (Cents/kWh) 0.045 “Click” once outside the
cell to view results.
• Gas Vacuum
www.gasfiredvacuum.com
• Fuel Based Nitrogen
www.industrialcenter.org
• Flame Treating Systems
www.flamesys@gte.net
Composite Radiant Tubes
www.griweb.gastechnology.org
www.flox.com
www.shunk-inex.com
• Fluidized Bed
www.rapidheattreat.com
(available soon)
• Applications
• Applications
• Applications
• Applications
Steel, Metal Heat Treating, Ceramic, Glass and other industrial processes
• Who to contact?
Three Groups referenced – GTI, WS Thermal & Shunk-Inex. Others are active.
See Web sites
Solution Heat Treat, Quench and Aging of aluminum castings (sand, squeeze
cast, foam core), and forgings in automotive and other industrial applications
• Who to contact?