seco/warwick s.a

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SECO/WARWICK S.A. SECO/WARWICK Ltd Ul. Sobieskiego 8 66-200 Świebodzin POLAND CAB LINE DESIGNS CAB LINE DESIGNS TO REDUCE ENERGY COSTS TO REDUCE ENERGY COSTS Piotr Skarbiński Global Product Director CAB Furnaces 4th 4th International Congress International Congress Aluminium Aluminium - - Brazing Brazing May May 16 16 - - 18, 18, 200 200 6 6 in in D D ü ü sseldor sseldor f f

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Page 1: SECO/WARWICK S.A

SECO/WARWICK S.A.SECO/WARWICK LtdUl. Sobieskiego 866-200 ŚwiebodzinPOLAND

CAB LINE DESIGNS CAB LINE DESIGNS

TO REDUCE ENERGY COSTSTO REDUCE ENERGY COSTS

Piotr SkarbińskiGlobal Product Director CAB Furnaces

4th4th International Congress International Congress ““AluminiumAluminium--BrazingBrazing””

MayMay 1616--18,18, 20020066 in in DDüüsseldorsseldorff

Page 2: SECO/WARWICK S.A

SECO/WARWICK S.A.

GOAL:GOAL:

TO PRESENT WHAT SCALE OF SAVINGS TO PRESENT WHAT SCALE OF SAVINGS

CAN BE ACHIEVED BY CAB LINE RUNNING CAN BE ACHIEVED BY CAB LINE RUNNING

USING THE DESIGN SOLUTIONS WHICH USING THE DESIGN SOLUTIONS WHICH

DECREASE ENERGY CONSUMPTIONDECREASE ENERGY CONSUMPTION

Page 3: SECO/WARWICK S.A

SECO/WARWICK S.A.

For all calculations a typical size brazing line

is used as the reference example:

Load parametres:

Type – radiator

Dimensions – 500 x 700 x 50 mm

Weight – 5 kg Al, 3 kg SS fixtures

Production – 100 pieces / hour

Quantity of oil 50 g/core

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LOAD CONFIGURATION

Degreaser belt speed – 833 mm/min

Dryer/brazer belt speed – 1083 mm/min

Page 5: SECO/WARWICK S.A

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SIZE OF REFERENCE EXAMPLE SYSTEM

Heated lengths:

Degreasing oven – 5000 mm

Dry-off oven – 5500 mm

Preheat chamber – 3800 mm

Braze chamber – 7600 mm

5000 5000 5500 5500 3800 3800 76007600

Heating times:

Degreasing oven – 6 min.

Dry-off oven – 5 min.

Preheat chamber – 3,5 min.

Braze chamber – 7 min.

Page 6: SECO/WARWICK S.A

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TEMPERATURE PROFILETEMPERATURE PROFILE

DEGREASING OVEN COOLING DEGREASING OVEN COOLING FLUXER DRYFLUXER DRY--OFF OVEN INLET TUNNEL PREHEAT CHAMBER OFF OVEN INLET TUNNEL PREHEAT CHAMBER BRAZE CHAMBER CLEAN BRAZE CHAMBER CLEAN WATER JACKET OUTLET AIR BLAST DRIWATER JACKET OUTLET AIR BLAST DRIVEVE

CHAMBER CHAMBER OUT CHAOUT CHAMBER COOLING CHAMBER TUNNEL MBER COOLING CHAMBER TUNNEL TABLETABLE

Page 7: SECO/WARWICK S.A

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POWER CONSUMPTION SPLIT FOR POWER CONSUMPTION SPLIT FOR

EACH UNIT OF THE LINEEACH UNIT OF THE LINE

100665Total

15101Braze

chamber

26172Preheat

chamber

22147Dry-off oven

37245Degreaser

%kW (gas)

Page 8: SECO/WARWICK S.A

SECO/WARWICK S.A.

DEGREASERDEGREASER

29%29%

9%9% 18%18%31%31% 13%13%

HEAT HEAT

TO TO

CORESCORESHEAT HEAT

TO TO

FIXTURESFIXTURESHEAT HEAT

TO BELTTO BELT

HEAT HEAT

TO DILLUTIONTO DILLUTION

AIRAIR

HEAT HEAT

THROUGHTHROUGH

CASINGCASING

Page 9: SECO/WARWICK S.A

SECO/WARWICK S.A.

DEGREASER & AFTERBURNERDEGREASER & AFTERBURNER

A F T E R B U R N E RD E G R E A S E R

10%10%

3%3%

6%6%

11%11%

5%5%60%60% 5%5%

HEAT HEAT

TO CORESTO CORES

HEAT HEAT

TO FIXTURESTO FIXTURESHEAT HEAT

TO BELTTO BELTHEAT TO HEAT TO

DILLUTION AIRDILLUTION AIR

HEAT THROUGH HEAT THROUGH

CASINGCASING

HEAT TO HEAT TO

DEGREASERDEGREASER

EXHAUST AIREXHAUST AIR

HEAT THROUGH HEAT THROUGH

CASINGCASING

Page 10: SECO/WARWICK S.A

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DEFINITIONS

DIRECT

Burners or Electric Heaters in the oven body

INDIRECT

NO Burners or Electric Heaters in the oven body

DEGREASER

POSSIBLE SOLUTIONS

Page 11: SECO/WARWICK S.A

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DIRECT

DIRECT FIRED with burners or electrical heaters in the oven body

EXHAUST FAN

BURNERS

MANUAL DAMPERS

Page 12: SECO/WARWICK S.A

SECO/WARWICK S.A.

DIRECT FIRED with burners or electrical heaters in the oven body

DIRECT FIRED WITH AFTERBURNER

AFTERBURNER

EXHAUST FAN

BURNERS

MANUAL DAMPERS

Page 13: SECO/WARWICK S.A

SECO/WARWICK S.A.

DIRECT FIRED DEGREASER WITH AFTERBURNER

Page 14: SECO/WARWICK S.A

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DIRECT FIRED with burners or electrical heaters in the oven body

DIRECT FIRED WITH HEAT RECOVERY HEAT EXCHANGERHEAT

EXCHANGERAFTERBURNER

EXHAUST FAN

BURNERS

MANUAL DAMPERS

Page 15: SECO/WARWICK S.A

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DIRECT FIRED SYSTEM WITH HEAT RECOVERY HEAT

EXCHANGER

Page 16: SECO/WARWICK S.A

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INDIRECT FIRED without burners or electrical heaters in the oven body

INDIRECT FIRED WITHOUT HEAT RECOVERY HEAT EXCHANGER

AFTERBURNER

EXHAUST FAN

AUTOMATIC

DAMPER

PRESSURE

SENSOR

MANUAL DAMPERS

AUTOMATIC DAMPERS

Page 17: SECO/WARWICK S.A

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INDIRECT SYSTEM

Page 18: SECO/WARWICK S.A

SECO/WARWICK S.A.

INDIRECT FIRED

INDIRECT FIRED WITH HEAT RECOVERY HEAT EXCHANGER

AUTOMATIC DAMPERS

MANUAL DAMPERS

EXHAUST FAN

HEAT

EXCHANDER

AFTERBURNER

Page 19: SECO/WARWICK S.A

SECO/WARWICK S.A.

INDIRECT FIRED

HEAT AXCHANGER MOUNTED IN DEGREASER

AUTOMATIC

DAMPER

PRESSURE

SENSOR

AFTERBURNER

EXHAUST FAN

MANUAL DAMPERS

AUTOMATIC DAMPERS

HEAT

EXCHANGER

Page 20: SECO/WARWICK S.A

SECO/WARWICK S.A.

DIRECT FIRED

DIRECT FIRED WITH CATALITIC OXIDISER

BURNERS

EXHAUST FAN

CATALITIC OXIDISER

MANUAL DAMPERS

Page 21: SECO/WARWICK S.A

SECO/WARWICK S.A.

CATALITIC OXIDISER

Page 22: SECO/WARWICK S.A

SECO/WARWICK S.A.

INVESTMENT

COST

ENERGY

CONSUMPTIONNOTES

DIRECT FIRED

WITHOUT HEAT

EXCHANGER

VERY LOW HIGH THE SIMPLEST SYSTEM

DIRECT FIRED WITH

HEAT EXCHANGERMEDIUM/LOW MEDIUM/LOW

COMPROMISE BETWEEN

INVESTMENT AND

RUNNING COST

INDIRECT FIRED

WITHOUT HEAT

EXCHANGER

LOW HIGHSIMPLE SYSTEM WITH ONE

HEATING SOURCE

INDIRECT FIRED WITH

HEAT EXCHANGERHIGH LOW

NO CONTACT OF

PRODUCTS OF

COMBUSTION WITH THE

LOAD - VERY HIGH HEAT

UP/SHUT DOWN TIME

DIRECT FIRED WITH

CATALITIC OXIDIZERVERY HIGH VERY LOW

ADDITIONAL COST OF

FREQUENT CATALISER

EXCHANGES

(EACH 2 YEARS)

INDIRECT FIRED WITH

HEAT EXCHANGER

MOUNTED IN THE

DEGREASER

HIGH/MEDIUM LOW

NO CONTACT OF

PRODUCTS OF

COMBUSTION WITH THE

LOAD

Page 23: SECO/WARWICK S.A

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245 DIRECT FIRED WITHOUT HEAT EXCHANGER

204 DIRECT FIRED WITH

HEAT EXCHANGER

185 INDIRECT FIRED WITH

HEAT EXCHANGER MOUNTED IN DEGREASER

171 DIRECT FIRED WITH CATALITIC OXIDIZER

177 INDIRECT FIRED WITH

HEAT EXCHANGER

205 INDIRECT FIRED WITHOUT HEAT EXCHANGER

POWER CONSUMPTION

(kW gas)

APPROXIMATE POWER CONSUMPTION

FOR DIFFERENT SOLUTIONS

OF DEGREASER/AFTERBURNER HEAT RECOVERY

Page 24: SECO/WARWICK S.A

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- Heat recovery from furnace to dryer

- hood between dry-off oven and braze chamber

- common belt through dry-off oven and braze chamber

- increased insulation thickness

- enlarging of system size

- heat recovery from air blast cooling chamber.

OTHER DESIGNING SOLUTIONS

TO REDUCE ENERGY CONSUMPTION

Page 25: SECO/WARWICK S.A

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DRYERDRYER

28%28%9%9% 17%17% 32%32%

14%14%

HEAT HEAT

TO CORESTO CORES HEAT HEAT

TO FIXTURESTO FIXTURES HEAT HEAT

TO BELTTO BELT

HEAT TO HEAT TO

EVAPORATEEVAPORATE

WATERWATER

HEAT HEAT

THROUGHTHROUGH

CASINGCASING

Page 26: SECO/WARWICK S.A

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DRYER – HEAT RECOVERY SYSTEM

HOT FLUES FROM BRAZER DELIVERED TO DRYER

- Savings for reference example: consumption of 147 by basic dryer

reduced to 102 kW (45 kW (gas) savings).

One One common combustion common combustion system system

exhaust exhaust for for dryerdryer, , preheat and preheat and

brazerbrazer

DRYERDRYERPREHEATPREHEAT

BRAZERBRAZER

Page 27: SECO/WARWICK S.A

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DRYER – HEAT RECOVERY SYSTEM

HOT FLUES FROM BRAZER DELIVERED TO DRYER

Page 28: SECO/WARWICK S.A

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PREHEATPREHEAT

11%11% 23%23% 6%6% 22%22%

HEAT HEAT

TO CORESTO CORES HEAT HEAT

TO FIXTURESTO FIXTURES HEAT HEAT

TO BELTTO BELT

HEAT HEAT

THROUGH THROUGH

CASINGCASING

38%38%

ATMOSPHEREATMOSPHERE

Page 29: SECO/WARWICK S.A

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BRAZERBRAZER

21%21%7%7% 13%13%

19%19%40%40%

HEAT HEAT

TO CORESTO CORES

HEAT HEAT

TO FIXTURESTO FIXTURES HEAT HEAT

TO BELTTO BELT

ATMOSPHEREATMOSPHEREHEAT HEAT

THROUGHTHROUGH

CASINGCASING

Page 30: SECO/WARWICK S.A

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HOOD BETWEEN DRYER AND BRAZER

- energy saving for the reference example lineis 20 kW (gas)

- additional advantage – increased brazingproductivity

Page 31: SECO/WARWICK S.A

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Common belt for dryer and brazer

- Energy saving for the referenceexample line is 27 kW (gas)

- additional advantage – increased

brazing productivity

Page 32: SECO/WARWICK S.A

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Increased insulation thickness - ovens

- for currently used mineral wool insulatingmaterials (thickness 150 mm) heat losses are

0,08 kW/m2 (15 kW for the reference example)

- further increasing of insulation can give onlyminor effect of energy saving.

Page 33: SECO/WARWICK S.A

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- for currently used insulating materials andthickness of 250 mm heat losses are 0,22

kW/m2

- by increasing the insulation thickness to 300 mm heat losses will be reduced to 0,18 kW/m2

- the energy saving for the reference example line is 12 kW (gas).

Increased insulation thickness – preheat and brazer

Page 34: SECO/WARWICK S.A

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Savings achieved by increasing system size

2 x 665 kW = 1330 kW

Doubled length: 1 x 1150 kW = 1150 kW

Redesigned configuration (2 loads on belt width):

1 x 1120 kW = 1120 kW

Page 35: SECO/WARWICK S.A

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Heat recovery from cooling chamber

In the air blast cooling chamber load, fixtures,

belt is cooled down from about 250ºC to

ambient temperature.

For the reference example line the energy

transferred to cooling air is appoximatelly 50

kW.

This energy can be recovered by using the air

for i.e. plant heating.

Page 36: SECO/WARWICK S.A

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Comparision of energy cost in aspect of natural gas

and electrical energy prices

20190,0450,28USA

27200,060,3Europe

Hourly electrical energy

consumption cost

for reference system

[EUR]

Hourly natural gas

consumption cost

for reference system

[EUR]

Elec.

energy

price

[EUR/kWh]

Natural gas

price

[EUR/Nm3]

Lands/

/continents

Page 37: SECO/WARWICK S.A

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CONCLUSIONS

0,03125.200105Increased system size

0,01512.00050Heat recovery from airblast cooling chamber

0,0042.90012Thermal wall losses

0,0086.50027Common belt

0,0064.80020Hood

0,01310.80045Heat recovery on brazer-dryer

0,012 – 0,0219.600 – 16.80040 - 70Heat recovery on degreaser

Savings on 1 piece of

heat exchanger for the

reference example line

[EUR]

Yearly cost saving based

on 8000 working hours

and natural gas price: 0,3

EUR/scm [EUR]

Saving of energy

for reference

example line

[kW gas]

Designing solutions

Page 38: SECO/WARWICK S.A

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CONCLUSIONSTOTAL SAVING AVAILABLE FOR REFERENCE

EXAMPLE BRAZING LINE

* 300 kW (gas) of savings possible to achieve on the line

of ~700 kW original consumption.

* 72.000, - EUR savings per year.

* 0,09 - EUR savings per core.

Page 39: SECO/WARWICK S.A

SECO/WARWICK S.A.

CAB line for precoated materials or paint flux

technology reduces energy consumption

Power saving for reference example of

CAB line is 130 kW (gas) in this case.

Page 40: SECO/WARWICK S.A

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Forced air cooling instead of

water jacketed in the atmosphere cooling section

The air cooling chamber eliminates water from the line

structure but increases energy consumption

(a level of 10 kW for the reference example).

Page 41: SECO/WARWICK S.A

SECO/WARWICK S.A.SECO/WARWICK LtdUl. Sobieskiego 866-200 ŚwiebodzinPOLAND

Telephone: +48 68 38 21 713 Facsimile: +48 68 38 21 757

Web Site: www.secowarwick.com.pl

Thank you for attention