Wide range of thermal processing plant shown
Manufacturer of thermal processing equipment and associated systems, has launched a new brochure to demonstrate its capability across a wide range of processes and sectors.
Elmetherm, manufacturer of thermal processing equipment and associated systems, has launched a new brochure to demonstrate its capability across a wide range of processes and sectors. The range has developed to include equipment for: resin encapsulation and curing applications; continuous curing of rubber extrusions; thermal degreasing and fluxing of automotive heat exchangers; drying of investment casting shells;radio frequency drying of foams and controlled temperature and humidity drying. The equipment is used in the automotive components, aerospace, foundry, food and pharmaceutical sectors.
Coupled with component handling systems this diverse range reflects an ability to provide turnkey solutions to customer specific applications anywhere in the world.
Process hardens and protects magnesium, aluminium
Surface treatment process is building quite a reputation as the preferred treatment for magnesium and aluminium alloys, providing the hardest and most corrosion resistant surfaces.
Abbey metal finishing Company (Amfin) of Nuneaton, UK, has recently bought a licence to use the very latest in surface engineering technology: the Keronite process. Keronite is building quite a reputation as the preferred treatment for magnesium and aluminium alloys, providing the hardest and most corrosion resistant surfaces available in these growth markets. The new technology is now available from Amfin’s high-tec facility, strategically placed in the heart of the Midlands.
Amfin was founded in 1947 and has become one of the most forward-thinking and professional metal finishing companies in Europe.
The company offers a very wide range of treatments and finishes under one roof, believing this to be the key to providing high quality service, quickly and efficiently without compromising the customer1s need for flexibility.
The ideal partner for Keronite, Amfin is able to handle small, specialised batches as well as large production runs and prides itself on an unusually clean, green working environment.
It was Russian scientists who first developed the Keronite technology, using the principles of plasma electrolytic oxidation to transform the surface of light metals into a hard, dense ceramic.
Today, those involved in the original research are working closely with the technical team at Amfin to develop Keronite’s full potential as an enabling technology in the UK’s automotive, aerospace and general engineering sectors.
‘Keronite offers superior protection against wear, corrosion and scratching’, says Mike Sanderson, Amfin’s Sales and Marketing Manager.
‘This will make it possible for a number of our customers to use lightweight alloys where this would not previously have been possible.
We can see the benefits that Keronite can bring to a number of automotive and aerospace applications where weight reduction is becoming more and more of an issue.
But there are a growing number of applications for magnesium in the consumer sector, such as bicycle frames, camera housings and mobile Ophone cases, where we would like to see some early success.’ ‘We were attracted to Keronite not only because of the outstanding performance benefits of the coating itself and the new markets that it can open up for us, but also because the process uses no chromium, no toxic chemicals and generates no hazardous waste.’ ‘It is not often that the UK surface treatment industry can claim a real breakthrough in technology, but we firmly believe that is what Keronite represents for us.
We are delighted with the new installation and are now looking forward to working with Keronite to develop new applications for this exciting technology.’
Keeping products cool without polluting
The Wedgwood factory has resolved the conundrum of how to meet Heath and Safety issues on cooling without introducing pollutants into the atmosphere.
The world famous Wedgwood factory in Stoke on Trent has resolved the conundrum of how to meet Heath and Safety issues on cooling without introducing pollutants into the atmosphere. Wedgwood has installed five Breezair evaporative cooling units within the flat shop on the first floor of the factory and has also purchased an additional four mobile Breezair units, which are used for spot cooling throughout the factory. All the Breezair systems were designed and supplied by Works Base Cooling in Bury St.
Edmunds, a leading supplier of evaporative air-cooling systems throughout the country.
Cooling within factories where kilns, ovens or furnaces are being used is always a health and safety problem.
Winter temperatures in the flat shop at the Wedgwood factory could reach up to 32degC due to the fact that the fine china has to be produced in a near sealed environment to prevent any pollutants contaminating the product.
Such is Wedgwood’s determination to ensure that its white china stays pure that it even filters the gas it uses as well as the water used in the manufacturing process.
Producing the china begins with the spray dryer, which forms the clay into granules.
This is then put into storage bins.
The granules are then vacuum sucked out of the bin into a hopper, then released in to the tool mechanism where the clay is pressed out into china plates.
Finally, the product is put onto a conveyor and then robotically placed onto the kiln car truck.
Being located in a high conductive unit heat expelled by the kilns is retained throughout the process and transferred to the workstations causing extremely high temperatures.
Historically, Wedgwood had used large ceiling fans, but this only recirculated the hot air.
The factory had never managed to crack the problem of providing cooling for the workstation areas where the workforce had to endure the high temperatures during long shifts.
The price of air conditioning was too prohibitive and other forms of cooling were rejected as they could result in contaminants entering the factory.
Evaporative coolers contain large filter pads, which are kept wet by a water distribution system.
Hot air is drawn through the pads by a powerful centrifugal fan and is cooled by the evaporative process.
In this way, the air is cooled without introducing any water droplets through aerosols to provide a constant flow of naturally, cooled, fresh air, without any air being recirculated.
The water scrubs out any impurities so water evaporated is pure and clean.
This method of cooling not only meet Wedgwood’s requirement for a pollutant free environment but also as the Breezair provides a gentle breeze rather than blowing cool air it would not circulate dust particles.
The five units have been strategically placed to provide cooling at each workstation reducing the temperatures by around 5øC, which has made a tremendous difference to the workforce.
‘The Breezair has worked really well and there have been some very positive benefits’, says Mark Andrew, Group Quality Improvement Manager at Wedgwood.
‘We have resolved the Health and Safety issue and although unquantified will have positive effects on absenteeism and production.’ Regarded as the most advanced evaporative cooling technology in the world, the environmentally friendly Breezair system is economic to install, cost effective to run and consumes less energy than conventional air-conditioning systems.
Far more versatile than standard cooling methods, Breezair is capable of providing sufficient cool air to overflow and prevent hot air entering a building.
Originally founded by Josiah Wedgwood in 1759, the Wedgwood name is synonymous with fine china and is renowned throughout the world.
All through the years Wedgwood has been sold to kings, queens, tsars, emperors and sultans and is universally prized and collected
Infra-red emitter heats coatings very rapidly
Water-cooled, short wave, infra-red emitter, which offers very high power densities, suits finishing operations, which require very rapid heating and for the heating of very thin coatings.
A new water-cooled, short wave, infra-red emitter, which offers very high power densities, is now available from Heraeus Noblelight, of Neston. It is particularly suitable for finishing operations which require very rapid heating and for the heating of very thin coatings. The new short wave emitter is based on the well-proven, Heraeus twin tube design and features new materials and innovative water cooling, which allow very high surface power densities of up to 1.2MW/m2 to be achieved.
(This compares with maximum surface power densities of a few hundred kW/mý for conventional infra-red emitters.) Because of the rapid heat-up rates, the water-cooled emitter can generate temperatures greater than 1000degC in the product to be heated within seconds.
The emitter has been developed to find application in areas such as drying thin, water-based dispersions in coil coating in the steel industry, heating glazings in the manufacture of roof tiles, rapid heating of metal plates to temperatures of around 900degC, applying heat and coatings under vacuum and drying varnishes on wooden boards.
Currently, the new emitters, which have an operating life of around 1500 hours, are available in four models, with heated lengths of 150mm, 310mm, 530mm and 800mm and power ratings from 2.9kW to 15kW.
Other lengths and powers can be manufactured to order.
Every emitter is fitted with gold reflectors to maximise the heat radiation and can be used with all conventional voltages.
The required cooling is 2-3 litres/min for emitters with heated lengths less than 500mm and 4-6 litres/min for emitters with heated lengths greater than 500mm.
Heraeus Noblelight, part of the multi-national Heraeus Group, specialises in the production and application of high quality energy sources covering the entire electromagnetic spectrum, from ultra-violet to infra-red.
It has over 40 years experience in infra-red technology and offers the expertise, products and systems to provide efficient and effective solutions to drying, heating and curing problems throughout industry.
Stainless steel oven cures rubber products
Walk-in rubber parts curing oven features a SS exterior with #4 brushed finish, Type 430 SS interior with continuously backwelded seam construction and 4in (101mm) insulated walls.
No. 920 is a gas-heated, 500degF (257degC) walk-in oven from Grieve, currently used for curing various rubber parts. Workspace dimensions measure 52in W x 48in D x 48in H (1321mm W x 1219mm D x 1219mm H).
350,000 BTU/h.
are installed in a modulating gas burner, while a 4,200ft3/min, 3-HP recirculating blower provides horizontal airflow to the workload.
This Grieve walk-in oven features a stainless steel exterior with #4 brushed finish, Type 430 stainless steel interior with continuously backwelded seam construction and 4in (101mm) thick insulated walls.
A top-mounted heating chamber is provided to conserve floor space, while a motorized damper on the exhaust accelerates the unit’s cooling.
Oven exhaust discharges into a Type 304 stainless steel scrubber with brass piping.
The scrubber uses recirculated water, sprayed by a 1-1/2HP pump into the exhaust, to remove particulates.
Workloads are carried on the unit’s dual shelf trucks, each with channel supports on 3-1/2in (89mm) centers.
A transfer dolly is provided to carry two trucks and features oven-to-dolly and dolly-to-truck latches for easy loading/unloading.
The oven has a 4in (101mm) insulated floor with two pairs of truck wheel guide tracks built atop the floor.
No.
920 has all safety devices required by IRI, FM and NFPA Standard 86 for gas-heated equipment, including a 650ft3/min, 1/2HP powered forced exhauster.
This oven also features a digital programming temperature controller, 10in diameter circular chart recorder and fused disconnect switch.
Heat treatment furnace has accelerated cooling
Gas fired heat treatment pallet furnace has two modulating natural gas burners with a floor mounted combustion air blower and an accelerated cooling system.
No. 925 is a gas-heated, 2000degF (1094degC) pallet furnace, currently used for heat treating. Workspace dimensions measure 30inW x 48inD x 36inH (0.76m W x 1.22m D x 0.91m H).
700,000 BTU/h are installed in two modulating natural gas burners with a floor-mounted combustion air blower.
This unit also includes a 325ft3/min intake pressurizing blower, with motorized dampers on the intake and exhaust for accelerated cooling.
This Grieve pallet furnace is provided with 7in thick insulated walls, comprising 5in of 2300degF ceramic fiber and 2in of 1700degF ceramic fiber.
The workload rests on a removable pallet with 7in thick insulation, comprising 4-1/2in thick 2300degF firebrick and 2-1/2in thick 2300degF firebrick.
Built to JIC/NEMA 12 electrical standards, No.
925 includes all safety equipment required by IRI, FM and NFPA Standard 86 for gas-heated equipment.
In addition, a 10in diameter circular chart recorder, digital programming temperature controller and recirculating blower airflow safety switch are onboard.
Oven lining material improves process stability
Lining a electro-dip oven with high emissivity material helped an automotive producer to meet a strict paint curing specification for a prestigious model.Ford Malaysia was struggling to meet a strict paint curing specification for a prestigious model with its existing electro-dip (ED) oven - 170degC for at least 20min. After evaluating a number of possibilities, FoM found that lining the ED oven with Fujihokka sheet proved to be the most feasible and cost effective. Fujihokka is a patented high emissivity material (90% emissivity over the 1-30 micron wavelength range).
The material has exceptional thermal properties and is ideal in heating, cooling or drying/curing applications to improve performance and save energy.
Boilers qualify for UK capital allowance scheme
Horizontal wet back fire tube boilers range is now available with optional ECA approved burners and has been incorporated on the Energy Technology List for the UK government backed ECA scheme.
Fulton Boiler Works (Great Britain) has announced that its recently launched nine-model RBC range of horizontal wet back fire tube boilers is now available with optional ECA approved burners and has been incorporated on the Energy Technology List for the government backed ECA (Enhanced Capital Allowance) scheme. The Inland Revenue, DEFRA and Department of Environment are working in collaboration with the Carbon Trust to operate the scheme enabling businesses to claim 100% of its first year capital allowances on investments, on qualifying energy saving technologies and products. The ECA scheme allows a business to write off the whole of the capital cost of their investment in these technologies against their taxable profits for the period in which the investment is made, which can deliver a helpful cash flow boost and a shortened payback period.
For new or replacement steam boiler installations, the scheme covers both capital plant and installation costs, and interest free ‘Action Energy Loans’ are also available to SMEs for boiler plant improvements and replacements.
To qualify for the Carbon Trust assessed and approved Energy Technology List, the approved RBC ECA boilers - offering capacities from 957 to 4787 kg/h - are fitted with NU-Way ECA specification burners which, as a packaged combination, reach the high levels of performance and efficiency required to meet the criteria.
‘We are delighted that the RBC ECA range has been included in the Energy Technology List.’ says Fulton’s sales and marketing director Gordon Bareham, who goes on to explain that high efficiency steam boiler plant not only qualifies for the ECA scheme, but also gives lower running costs at a time when rising energy costs are a concern to all.
Infra-red system dries non-slip coating for mats
A carbon infra-red system is helping a manufacturer to achieve the quality of non-slip coating required on disposable tray mats to meet the stringent demands of passenger airlines.
A carbon infra-red system from Heraeus Noblelight, of Neston, is helping Orvec International to achieve the quality of non-slip coating required on disposable tray mats to meet the stringent demands of major passenger airlines. Orvec International is a world leader in the design and manufacture of hazard protective workwear and passenger care products. Its range of disposable tray mats can be in paper or crepe, coated and uncoated and printed to a very high standard.
When the Kingston-upon-Hull company recently decided to introduce a new range of non-slip tray mats to meet the specifications of a major airline, a new manufacturing line was set up and the manufacturing technology was adapted to allow an extremely high quality non-slip coating to be applied.
The process required infa-red radiation treatment at high speeds and Orvec contacted Heraeus, who carried out proving trials at its Applications Centre in Neston.
These established that a carbon infra-red system could achieve the required result at web speeds of up to 70m/min and, as a result, a full-size system was installed at Orvec.
This consists of two, 20.7kW carbon infra-red cassettes, each containing nine, 2.3kW carbon infra-red medium wave emitters.
The cassettes can be operated individually by means of a closed loop thyristor control system to ensure precise drying profiles.
Since installation, the infra-red system has proved to be highly energy-efficient and its high power density has ensured that the applied coating is treated effectively to give a high quality finish.
The fast response of carbon infra-red has also proved important in this application, as the heating can be switched off very rapidly if needs be, so preventing any damage to the web in the event of production line breakdown.
Following successful operation of the system over a number of months, Orvec decided to see if line speeds could be increased even more, to meet rising customer demand for the non-slip trays.
Accordingly, a 7kW carbon infra-red was retrofitted and this has allowed a further 30% improvement.
Heraeus Noblelight, part of the multi-national Heraeus Group, specialises in the production and application of high quality energy sources covering the entire electromagnetic spectrum, from ultra-violet to infra-red.
It has over 40 years experience in infra-red technology and offers the expertise, products and systems to provide efficient and effective solutions to drying, heating and curing problems throughout industry.
Boiler maker offers design and build service
Fulton Boiler Works, a part of the Fulton Group of companies, which has manufacturing operations in the UK, US and China, has an enviable reputation for manufacturing efficient and reliable boilers. Due to the success of sales of its packaged and skid-mounted boiler systems and plant rooms over the past few years, the company is offering a significantly enhanced service to customers that includes design and build, applications advice and worldwide after sales support. Any of the boilers in Fulton’s range can be designed and built as single or multiple skid-mounted systems or plant rooms, for the most complicated environments, even those with poor access.
The systems can be supplied with all necessary ancillary plant for a range of applications and the high-efficiency and fast recovery properties for steam raising, make them ideal for large, medium or small plant installations.
All systems are built in Britain to the relevant standards and are available for electricity, gas and oil firing, with duties from 14kg/h to 3350kg/h F and A 100 deg C.
They are designed to be delivered to site and installed on a prepared concrete base.
Final installation is made easier by connecting to termination points, pre-installed by the customer, to ensure that the new boiler plant matches existing site services.
As well as its design and build service - and as a safeguard to end-users - Fulton is now overseeing the installation and commissioning of its boilers and systems and providing regular servicing and maintenance contracts and training.
The after-sales support is supervised by Fulton’s service manager Steve Robinson and backed by a team of six service technicians and a number of nominated service contractors, offering national and international service support.
‘We are already providing after-sales service and support in the UK, Europe, Middle East, Kazakhstan, Russia, and the Caribbean.’ explains Robinson.
‘In fact, two oil-fired RBC boilers have recently been installed and commissioned as part of a turnkey project for an animal feed mill in Saudi Arabia.’ For working on gas boilers, Corgi and ACOPS approval is essential and an annual service and inspection mandatory; if boiler duty is heavy, an interim six-month service is also recommended.
Regular servicing and maintenance by a recognised and qualified service organisation or engineer is also essential for steam boilers, to maintain optimum operating efficiency, safety and long-term reliability.
To ensure that Fulton boilers are correctly maintained and serviced, especially for companies operating a number of boilers, Fulton offers an enhanced training scheme for service engineers and boiler operatives.
Explains Robinson: ‘When you buy a Fulton fuel-fired boiler, commissioning and its first six months servicing are included, as well as a provision for training site operatives on routine operating and maintenance procedures.’ Comprehensive hands-on training can be provided on-site or at Fulton’s headquarters in Bristol.
It covers all aspects of service including product information, day-to-day operation, servicing and maintenance and is structured to the needs of individual’s or companies.
For example, if the boiler is to be serviced by a dedicated service company, Fulton can train its engineers, however if it is owner maintained, the training can focus on the particular boiler and application.
With properly managed maintenance, a steam boiler will give excellent and efficient service for many years, infact Fulton still service boilers that are over 30 years old!