asm met14_debashis_linde

28
Improving Furnace Atmosphere Circulation with High-Speed Gas Injection System By Debashis Roy Linde India Limited

Upload: debashis-roy

Post on 15-Aug-2015

74 views

Category:

Documents


1 download

TRANSCRIPT

Page 1: ASM MET14_Debashis_Linde

Improving Furnace Atmosphere Circulation with High-Speed Gas

Injection SystemBy

Debashis RoyLinde India Limited

Page 2: ASM MET14_Debashis_Linde

• Annual Sales (EURO):15 billion

• Employees worldwide: 55,000

• R&D spending (Euro): 9 million

• No. of patents: >2,800

• Global Presence:>100 countries

World’s leading gas company & Solution Provider for gases

Page 3: ASM MET14_Debashis_Linde

Filling centre

Pipeline

Pipeline

On-site supply

Retailer

Transport of liquefied gas

Cust

omer

Cylinder

Bulk

Tonnage

Gases production plant

Gas Supply Capabilities

Page 4: ASM MET14_Debashis_Linde

• Distortion and Quality Control

• Cost of Energy

• Environmental drivers

• Implementation of modelling and simulation technologies

• Problems with quenchant selection and use

• cost of Equipment

• Analysis Technique and Equipment

• Process optimization and Control

Key Challenges

Page 5: ASM MET14_Debashis_Linde

An operation or combination of operations involving the heating and the cooling of

a metal or alloy in the solid state to attain certain desired properties.

The functions of furnace atmosphere— To prevent/reduce oxidation

— To achieve bright surface

— To adjust the surface chemistry of the components

Atmosphere gases used in Heat Treatment

Neutral

Gases

Active Gases

Reducing Oxidizing Decarburizing Carburizing Nitriding

Ar H2 H2O H2O CO NH3

N2 CO CO2 CO2 CxHy

He O2 O2

Why Heat Treatment & Why Furnace Atmosphere?

Page 6: ASM MET14_Debashis_Linde

What is CARBOJET®

Inject small amount of gas with high velocity

Placed in one or several position on the furnace

Pit furnaces, Roller Hearth Furnace…

Annealing, carburizing, hardening …

Better gas convection in Heat Treatment furnaces

Improved furnace atmosphere homogeneity

Fan and inner retort can be removed

Increase heat transfer

Reduced energy/water consumption

Easy maintenance, No vibrations

What are the advantages of CARBOJET®?

CARBOJET® - General Idea

Page 7: ASM MET14_Debashis_Linde

Principle – Atmosphere uniformity What kind of problems need to be solved

The CARBOJET® Solution

Evaporating or change of chemical

composition from the product

surface or addition of reactive or

inert gases have to be uniformly distributed to ensure the specified

heat treatment results.

In several heat treatment processes the atmospheric

gas convection is extremely low. This causes:

inhomogeneous composition of local atmospheres

uneven product quality, sooting, and problems in

heat and carbon transfer

Fan might help, but usually they cause other problems

due to air leakage and high service and maintenance costs

With high speed gas injection it is possible to move the furnace atmosphere and

create gas circulations, which improve the convection and increase the heat and

carbon transfer rates.

CARBOJET® - General Principles

Page 8: ASM MET14_Debashis_Linde

Solution Description

The system consists of one or several

CARBOJET® high speed nozzles with

piping and flow train

The number of nozzles is adapted to the

furnace size and existing gas

consumption

Gas flows can be controlled manually or

through a CARBOFLEX® atmosphere

control solution

The specially designed nozzles are made

of heat resistant material to ensure a long

lifetime

All CARBOJET® systems are tailor-made to

optimally suit each customers needs

N2

CH3OH

NG

CH4

CARBOJET® - Solution Description

Page 9: ASM MET14_Debashis_Linde

Added values:

Increased productivity due to faster

carburization processes

Homogeneous product quality due to

improved atmosphere mixing

Reduced soot formation and better

utilisation of carburising gases

Increased carbon transfer on material

surfaces due to forced convection

Savings on maintenance, energy and

water (e.g. no fans needed)

Better quality

Cost savings

Higher Productivity

CARBOJET® - Solution Description

Page 10: ASM MET14_Debashis_Linde

m/s

CARBOJET® - Solution Description

Page 11: ASM MET14_Debashis_Linde

• Test run to prove CARBOJET®

• 2 identical trials were prepared for

» conventional with fan (1200 rpm)

» fan off and special CARBOJET® lance

• Load: forging scrap 183 kg C15 (0.15 % C)

• Retort diameter 900 mm, height 3mtrs

• Carburising temperature 910 °C, C-pot. 1.0 %, 10h

30min

• Protective gas : 2.1 m3/h N2, 1.7 l/h methanol

• Process control with Lambda probe

• 4 thermocouples

• 12 test samples of which 6 were analysed

CARBOJET® - Customer Case Study Pit Furnace

Page 12: ASM MET14_Debashis_Linde

Velocity (m/s)

With Fan CARBOJET with fan off

Empty furnace

CARBOJET® - CFD Simulation Pit Furnace

Page 13: ASM MET14_Debashis_Linde

Fan with cylinder

m/s

Fan without Cylinder CARBOJET® without cylinder

CARBOJET® - CFD Simulation Pit Furnace

Page 14: ASM MET14_Debashis_Linde

Temperature without CARBOJET®

Temperature difference min/max +/- 4°C

Temperature with CARBOJET®

Temperature difference min/max +/- 1°C

CARBOJET® - Customer Case Study Pit Furnace

Page 15: ASM MET14_Debashis_Linde

Better homogeneity with CARBOJET®

Depth (mm) Homogeneity of %C

With FanWith

CARBOJET®

0 0.05 0.03

0.1 0.06 0.04

0.2 0.05 0.05

0.3 0.06 0.05

0.4 0.06 0.04

0.5 0.06 0.04

0.6 0.05 0.03

0.7 0.03 0.03

0.8 0.05 0.03

0.9 0.04 0.02

1 0.03 0.02

Average 0.049 0.035

Test Result• Faster Heating rate

• Temperature and case depth are more

uniform

• The lid construction can be simplified

• Savings for maintenance and energy

• Less soot formation

• Applicable with all different processes

The customer has introduced CARBOJET®

in all his furnaces.

CARBOJET® - Customer Case Study Pit Furnace

Page 16: ASM MET14_Debashis_Linde

Sennestahl GmbH in Bielefeld, Germany•Two pit furnaces for several Heat Treatment processes

•Installations were made on August 2005 and January 2006

•With CARBOJET® it was possible to operate the pit furnaces

without fans Significant savings on maintenance costs

D. Holzenbecher, production manager of Sennestahl:“Broken ventilators are now history. I’m very convincedthat this technology is a success in our rough, non-stop

operation. The heating elements, retorts and brick lining

suffer less frequent damage. We’ve already seen a

noticeable reduction in maintenance costs.

These cost savings wouldn’t been possible without the

introduction of CARBOJET ®.”

CARBOJET® - Customer Case Study Pit Furnace

Page 17: ASM MET14_Debashis_Linde

High speed nozzles are installed through the furnace

wall, roof, cover., bottom

Gas flow is usually controlled with a control system

(CARBOFLEX®, CARBOTHAN, …)

Possible also to control the flow manually with a

simple flow meter (not best practice)

Very little maintenance needed since there are no

moving parts and the nozzles are heat and wear

resistant

Nozzle details (position, angle, amount) and gas flow

has to be defined separately for each furnace

High-speed nitrogen is the main gas component and it

is usually accompanied with methanol. It is possible

also to add propane, ammonia or natural gas with the

jet.

CARBOJET® Solution Package

Page 18: ASM MET14_Debashis_Linde

MHP Mannesmann Präzisrohr GmbH in Brackwrede, Germany

Two Roller Heart Furnaces for carbon steel tube annealing

First furnace equipped with CARBOJET® in 2005

CARBOFLEX® control system and in-situ endogas generators

CARBOJET® - Customer Case Roller Hearth Furnace

Page 19: ASM MET14_Debashis_Linde

Benteler AG, Germany

CARBOJET® on Roller Heart Furnaces for carbon steel tube annealing

Improved atmosphere homogeneity

Reduced soot formation and better utilisation of gases

CARBOJET® - Customer Case Roller Hearth Furnace

Page 20: ASM MET14_Debashis_Linde

Heating Zone

Each red arrow represents a CARBOJET® Lance. N2 amount: 10 Nm³/h and per Lance.

CARBOJET® - Customer Case Roller Hearth Furnace

Page 21: ASM MET14_Debashis_Linde

With CARBOJET®

Without CARBOJET®

CARBOJET® - CFD Simulation Roller Hearth Furnace

Page 22: ASM MET14_Debashis_Linde

• Manufacturing of electric connecters

• Increases productivity by 15%

• More homogeneous atmosphere

• Less soft spots

• More precise atmosphere control

• Longer life of the retort

CARBOJET® - Customer Case Rotary Retort Furnace

Page 23: ASM MET14_Debashis_Linde

Furnaces where CARBOJET®® used successfully Roller hearth furnaces

Walking beam furnace

Rotary retort furnaces

Pit furnaces, etc

Furnaces where CARBOJET®® can work

Batch furnaces without a fan

Rotary hearth furnaces

Mesh Belt furnaces

SQF, etc

HT processes suitable for CARBOJET®®

Annealing, Carburising, Carbo-nitriding,

Hardening, Nitriding, Nitrocarburising…

CARBOJET® - Suitable Furnaces And Processes

Page 24: ASM MET14_Debashis_Linde

• Low maintenance costs –The elimination of problematic mechanical fans

• Reduced down time - No down time required for mechanical fan maintenance.

• Infinite turndown – CARBOJET® nozzles can be turn on and off at will

• Compositional flexibility – Quick change of atmospheres and the application of

different gases.

• Improved quality – less scrap due to better control of the atmosphere

• Improved consistency - Due to uniform distribution of the furnace atmosphere

• Other major benefits –Heating elements, retorts and brick lining suffer less

frequent damage.

CARBOJET® - Feedback from Customers

Page 25: ASM MET14_Debashis_Linde

• “CARBOJET® Roller Hearth Furnace“ at several companies

• Jansen (CH), Benteler (x2), Zollern, MHP(x2), Poppe & Potthoff(x2), Železiarne Pobrezova (SK).

• Satisfied customers, quality improves, costs savings, higher productivity

• “CARBOJET® Rotary Furnace” (x3) at Weidmüller with measurable results!

• Productivity increases by 15% in tool carburizing after installing CARBOJET®

• “CARBOJET® Pit Furnace” (x2) at Sennestahl, Sandvik (SK) with promising results

• The pit furnace fan could be replaced with CARBOJET®

• “CARBOJET® Cooling Zone” Železiarne Pobrezova (SK), installation at Jansen (CH)

• More than 10% faster cooling rate

CARBOJET® - References

Page 26: ASM MET14_Debashis_Linde

Since 2005, Linde has successfully commissioned 100+ CARBOJET® installations in

practically different types and sizes of heat treatment furnaces, with Process

Performance Guarantees.

Linde’s CARBOJET® injection solutions have proven to deliver

– Improved quality and consistency of product

– Improved furnace atmosphere homogeneity

– Reduced maintenance cost and energy cost

– Improved temperature uniformity

– Reduced soot formation

Results from Successful Use of CARBOJET®

Page 27: ASM MET14_Debashis_Linde

CARBOFLEX®

ACS: Control System CARBOJET® CARBOTHAN®

HYDROFLEX®

Non-Ferrous Annealing Ferrous annealing Brazing

CRYOFLEX®

FRIOFLEX®

SINTERFLEX®

ACS: Control System SINTERFLEX SH SINTERFLEX MIM

LINDE Product Families for Heat Treatment Applications

Page 28: ASM MET14_Debashis_Linde

Thank youfor your kind attention

Creating Customer Value as a Solutions Provider

Debashis RoyMob: 9004061367

[email protected]