Industrial Heating June 2011

June 2011

June 28 - July 2, 2011 • Düsseldorf, Germany Official North American Media Co-Sponsor

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ASM HTS insider p.63 Energy-Saver Update p.67

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Regenerative vs. Oxyfuel Burners p.41 Cutting Electric Costs p.45 Insulation for Efficiency p.51 Optimizing Alloy for Conservation p.57

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Publication Official publication of ASM’s Heat Treating Society • www.industrialheating.com

Ensuring Certainty

Reaching new Heights in Hardness Testing DuraVision - Struers Newest Universal/Macro Hardness Tester A fully automatic universal and macro hardness tester with innovative features and increased automation is a natural complement to any production environment testing large or heavy samples in cast iron, steel and aluminum. The DuraVision creates ef¿ciencies in a production environment. An entire test cycle of load application, indentation, focusing, illumination adjustment and hardness evaluation is now carried out automatically – thereby ensuring 100% repeatability in testing. It’s fast, simple and accurate.

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For more information about Struers complete hardness testing product range, contact your local Struers representative at 1.888.STRUERS (787.8377) or visit our website at www.struers.com.

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Unique test load range from 1 kgf – 3000 kgf (1-250 kfg or 20-3000 kfg) providing versatility in testing applications High quality optical system with automatic illumination adjustment Automatic test cycles including autofocus and automatic hardness evaluation Touch screen operation Intuitive workÀow oriented software Motorized vertical test head for maximum height capacity and ¿xed, yet expandable, anvil for an uncompromised and stable test environment

Telephone: 888.STRUERS (787.8377) | Email: [email protected] | Web: www.struers.com

Ipsen delivers energy savings. The TITAN® Cost & Environment Simulator is an easy step-by-step vacuum heat treat process analyzer. Plug in your parameters and in moments get a detailed report showing exactly what your cost and energy savings will be with TITAN®. Try it today at www.TitanCostSavings.com and see how much you can save.

SPEED UNIFORMITY EFFICIENCY

Industrial Heating’s Web Search Power Pages BURNERS & COMBUSTION EQUIPMENT

CERAMICS

Eclipse, Inc.: Recuperative Burners

Ceramic Solutions

Eclipse offers the best in combustion products, systems and technical service for customers around the world, delivering safe, reliable, efficient and clean equipment for a wide range of heating applications. Contact: Patrick O’Keefe, 815-877-3031 www.eclipsenet.com

Ceramic Solutions is a sales and distribution company specializing in technical ceramics. We offer closed and open end, feed-through, immersion, multi and single bore, top hats, furnace, heating element and support tubes and insulators, ribbed, grooved, flat, hearth and setter plates, rollers and AL99.8 labware. Contact: Bill Bolt, 936-588-2646 www.ceramicsolutionsconroe.com

Hauck Manufacturing Co. Hauck Manufacturing Company offers a wide range of combustion products including burners, blowers and controls and Kromschroder burners and control products. Contact: Michael Shay, 717-272-3051 www.hauckburner.com

WS Thermal Process Technology: High-Efficiency Burners We offer the most efficient direct-fired and radiant tube burners and are a world leader in ceramic radiant-tube technology with over 15 years of experience. Contact: Lee Rabe, 440-365-8029 www.flox.com

Yeten Yeten has been working on the heating systems of industrial furnaces for 25 years. We produce burners and control equipment for our customers. Contact: Ibrahim Turan, +90 216 420 22 18 www.yeten.com

BUSHINGS & BEARINGS

COOLING SYSTEMS Dry Coolers, Inc. Dry Coolers, Inc. is a major supplier of industrial cooling systems and professional engineering services. Dry Coolers is experienced in working with contractors to assist in the design and manufacture of industrial process cooling solutions. Our cooling systems range in size from small point-of-service cooling to large, complex plant-wide systems. Contact: Brian Russell, 800-525-8173 www.drycoolers.com

CONTROLS, INSTRUMENTATION & TESTING EQUIPMENT AFFRI Inc: Testing Equipment AFFRI Inc. is a manufacturer and seller of Rockwell, Rockwell/ Superficial, Brinell, Micro/Macro, Vickers/Knoop, universal and portable hardness testers. We offer custom in-line hardness testing. Contact: Roberto Affri, 224-374-0931 www.affri.com

Graphite Metallizing Corp.

Struers Inc.

Self-lubricating, dimensionally stable GRAPHALLOY bushings endure temperatures to 1000°F as well as extreme chemical/ mechanical stresses. Applications include ovens, dampers and kilns. Contact: Eric Ford, 914-968-8400 www.graphalloy.com

Worldwide leader in materialography providing an entire range of equipment and consumables for specimen preparation; extensive line of hardness testers and microscopes providing a full range of comprehensive lab solutions. Contact: Bill Thompson, 888-STRUERS (787-8377) www.struers.com

THE DIFFERENCE IS OBVIOUS. The Brightest Solutions Through Ingenuity

Solar stands out from the usual choices. 4 June 2011 - IndustrialHeating.com

Visit www.solarmfg.com to learn more.

PROUDLY MADE IN THE USA

Industrial Industrial Heating’s Heating’s Web Web Search Search Power Power Pages Pages FURNACES & OVENS cont.

FLUIDS ASCO Numatics

Surface Combustion, Inc.: Heat-Treating Furnaces

ASCO Numatics offers comprehensive fluid automation solutions, including fluid control and fluid power products, for a wide range of industry-focused applications. www.asconumatics.com

Industrial manufacturer of heat-treating furnaces, including controlled carburizing, nitriding and vacuum carburizing. Surface Combustion offers continuous or batch furnaces with atmosphere gas generators and process controls. Contact: Daniel E. Goodman, 419-891-7150 www.surfacecombustion.com

FURNACES & OVENS Can-Eng Furnaces, Ltd.: Furnaces, Heat Treating Leading North American designer and manufacturer of heattreating equipment for ferrous and nonferrous metals. Products include furnaces, auxiliary equipment, atmosphere generators and process-control systems. Quality management system is registered to ISO 9001:2000. Contact: Steve Cropper, 905-356-1327; [email protected] www.can-eng.com

Centorr Vacuum Industries Centorr Vacuum Industries offers its new MIM-Vac ‘M’ line of custom metal hot-zone furnaces for Metal Injection Molding and handles all binders and feedstocks. Contact: Scott Robinson, 603-595-7233 www.centorr.com

Wellman Furnaces: Heat-Processing Systems Specializing in continuous or batch process; small or large loads; long or shot cycle; fixed or variable process; electric or fuel fired. Contact: Bob Longstreet, 317-398-4411, ext. 211 www.wellmanfurnaces.com

Wisconsin Oven Corp.: Ovens Wisconsin Oven offers: custom and standard models; gas or electric; temperatures to 1400˚F; factory tested and adjusted. Contact: Gary Hanson, 262-642-3938; [email protected] www.wisoven.com

HEATING ELEMENTS G-M Enterprises: Heat-Treating Furnaces G-M manufactures a wide range of furnaces, including vacuum, box, bell, batch and continuous. Contact: Suresh Jhawar, 951-340-4646 www.gmenterprises.com

Ipsen Inc.: Heat-Treating Equipment Ipsen manufactures, retrofits and services vacuum and atmosphere thermal-processing equipment for TurboTreater, TITAN, MetalMaster,VFS HEQ/HIQ/VDS, aluminum brazers, vacuum carburizing, vacuum oil quench, Ivadizer and atmosphere products. Contact: Mark Heninger, 815-332-2512 www.ipsenusa.com

Pyromaitre Through innovative energy-saving solutions and process expertise, Pyromaitre delivers precision heat-transfer ovens with the lowest total cost of ownership. Contact: 418-831-2576 www.pyromaitre.com

SECO/WARWICK Corp: Heat -Treating Equipment Heat-treating equipment manufacturer offers Metal Minutes Newsletter and Heat Treating Data Book free of charge - click at the link at the top of our home page and sign up today! Contact: Wojtek Modrzyk, [email protected] www.secowarwick.com

INEX INEX offers a wide range of composite radiant tube shapes including straight-through, U-tubes, closed-ended and segmented in various lengths and diameters. Contact: Mike Kasprzyk, 716-537-2270 www.inexinc.net

HOT ZONES Americarb: Hot Zone Replacement Complete hot-zone replacement kits at industry competitive pricing. Replacement kits for many vacuum furnaces, including DSS, CZ and ALD hot-zone models. Contact: 419-281-5800, [email protected] www.americarb.com

INDUCTION HEATING EQUIPMENT CEIA USA CEIA manufactures induction heating generators, controllers and pyrometers that enable closed-loop feedback for precision heating. Designed for seamless integration into automation, CEIA’s generators can handle endless applications. Contact: 330-405-3190 www.ceia-usa.com

IndustrialHeating.com - June 2011 5

Industrial Heating’s Web Search Power Pages INDUCTION HEATING EQUIPMENT

Unifrax

cont.

Induction Tooling, Inc.: Induction Equipment & Services Induction Tooling is widely recognized as the premier manufacturer of tooling for induction hardening. Our excellent reputation is the result of building high-quality inductors. Contact: David Lynch, [email protected] www.inductiontooling.com

Inductotherm Group: Thermal-Processing Equipment Inductotherm Group is a fully global group of manufacturing companies providing products such as: induction melting, induction heating and heat treating, induction welding, and vacuum induction melting and refining systems. Contact: Lauren Trimble, 609-267-9000 www.inductothermgroup.com

High-temperature insulation products including Fiberfrax ceramic fiber, Insulfrax and Isofrax soluble fiber, and Foamfrax thermal insulation. Contact: Virginia Cantara, 716-278-3832 www.unifrax.com

THERMOCOUPLES NANMAC Corporation: High-Performance Thermocouples & RTDs NANMAC offers a full line of standard and custom thermocouples and RTDs for replacement, OEM and Research applications. NANMAC also has Inventory stocking programs to suit your needs. Contact: Doug Joy, 508-872-4811; [email protected] www.nanmac.com

VACUUM PUMPS

REFRACTORIES & INSULATION

Oerlikon Leybold Vacuum

SGL Carbon Group

The Oerlikon Leybold Vacuum line of dry-compression vacuum pumps now features improvements in leak tightness, energy efficiency and physical stature over competitive brands. Contact: Mario Vitale, 800-764-5369 www.leyboldchampion.com

SGL is a full-service material supplier specializing in hightemperature applications and customer support. Contact: Lee Young, 610-670-4070 www.sglcarbon.com

Furnace & Thermal Automation Systems for Metals Processing Furnace Types

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TECHNOLOGY CONTINUOUS FURNACES

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Single and Multi-Row DesignsQ QGas-Fired and Electrically Heated UnitsQ QWide Range of Process ApplicationsQ QVarious Levels of AutomationQ QBelt, Pusher, Roller Hearth, and Rotary StylesQ QWide Range Of Companion EquipmentQ

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CONTENTS

June 2011 • Vol. LXXIX • No. 6

On the Cover:

A R T I C L E S

As a cost of doing business, energy is a much more significant component than it was a few decades ago. The article on p. 45 focuses on what we can do to save electricity.

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Regenerative Burners or Oxy-Fuel Burners for Your Furnace Upgrade? Jared S. Kaufman & Josh Marino – Tenova Core; Coraopolis, Pa. Recent furnace combustion system upgrades are being motivated by the desire to increase production, reduce CO2 and save energy costs. Of the available technologies, two of the most intriguing are regenerative burners and oxy-fuel burners.

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Heat Treating

Cut Costs and Stay Competitive with Advanced Energy Management Bob Zak – Powerit Solutions North America; Seattle, Wash. With the economy still challenging and competitive pressures continuing to rise, reducing expenses is imperative for industrial businesses. Yet many underestimate or neglect a key source of savings – the electricity bill.

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F E A T U R E

Industrial Gases/Combustion

Ceramics & Refractories/Insulation

It’s Easy Being Green Wendell Keith and Reto Fehr – Keith Company; Pico Rivera, Calif. Today, in our energy- and environmentally conscious society, being green is politically correct. It represents good environmental stewardship, and it is more profitable for your company to become green than you may realize!

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Heat & Corrosion Resistant Alloys/Composites

Energy Conservation through Proper Selection of Heat-Resistant Alloys Richard J. Grimm – Wirco, Inc.; Avilla, Ind. Energy conservation has become one of the primary issues for the heat-treating industry in the new millennium. It is important in this new business climate to look at all opportunities for increased furnace efficiency, including cast or fabricated alloy tooling.

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COLUMNS 14 Editorial CO2-Reduction Contrarian Energy savings is good for our companies and good for our world. But we should engage in energy-saving efforts for the best reasons. In spite of what we hear from most media sources, CO2 reduction is not one of the best reasons. Read the full editorial to learn why.

16 Federal Triangle Debt, Deficit and Spending – A Financial Outlook According to Barry Ashby, U.S. citizens should be prepared to face high inflation, energy costs of two to fourfold increase, problems in bank lending and continued outflow of industrial production to more hospitable venues in six to 12 months.

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18 The Heat Treat Doctor™ Martensite “Martensite is our friend,” so sayeth the heat treater, but what is martensite, really? And why is a tempered martensitic structure the single-minded goal of every heat treater when hardening steel?

22 Environmental & Safety Issues Solid-Waste Netherworlds “The more you explain it, the more I don’t understand it.” Mark Twain certainly would have had a field day commenting on today’s complex world of environmental regulations.

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24 MTI Profile – Metallurgical High Vacuum Corporation 26 IHEA Profile – IHEA Announces 2011-12 Officers, Board 28 Blogs in Print A new, periodic feature begins this month as we focus on one or more recent blogs and take a look at social media. June’s spotlight is on a new blogger, George Vander Voort, and his first blog post. Also, check out our Facebook friend of the month.

SPECIAL SECTIONS 63 HTS insider News from the ASM Heat Treating Society

DEPARTMENTS

39 Industry Events

72 Classified Marketplace

61 Literature Showcase

78 Advertiser Index

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70 Aftermarket

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36 IH Economic Indicators

67 ENERGY-SAVER UPDATE y Cons A look at the latest est erg er En energy-saving products and technologies the industry has to offer. U

66 Products

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30 Industry News

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INDUSTRIAL HEATING (ISSN 0019-8374) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: INDUSTRIAL HEATING, P.O. Box 2147, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to INDUSTRIAL HEATING, P.O. Box 2147, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

10 June 2011 - IndustrialHeating.com

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HEAT

Industrial Heating is the official publication of ASM’s Heat Treating Society and official media partner of ASM’s HT Expo & Conference.

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Consistent design & quality assurance Anchor-Loc 3 module design features construction from a continuous fold of spun blanket, stainless steel alloy hardware and center mount attachment. The design allows for consistent furnace layout, ease of installation and dependable service life. All components meet or exceed established industry standards assuring the same high quality worldwide.

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Online Exclusive Backfill Gases, Surge Tanks and Distribution Piping for Gas Storage Systems

N New “Expert” George G Vander Voort – V M Metallography

Selecting the proper backfill gas and backfill system is a key aspect in proper operation of any vacuum system, whether they are for a partial-pressure atmosphere, a process gas, a quench gas or a gas used to equalize pressure between chambers for load transfer or removal.

Everyday Metallurgy The Titanic – A Study in Metal Failure The story of the Titanic is a tragic tale of life lost. We have long been intrigued with the reasons why this catastrophe occurred. Design certainly played a role, but other similarly designed ships had useful service lives. At least one “cause” can be attributed to the metal used to make the hull of the ship. The melting and forming of this material certainly contributed. An article from 1998 explains why.

George Vander Voort G iis a consultant for Struer Str uerss Lat Latrob robe e Ste SSteel te and Scot Forge. Struers, Latrobe He is also president of Vander Voort Consulting. Vander Voort has more than 40 years of industry experience and has authored more than 280 publications. A member of ASM International since 1966, he has won 34 awards for his work in metallography.

FREE Webinar June 29, 2:00 p.m. Metallography of Welds Hosted by IH; sponsored by Struers

Snap tag to register for this webinar

www.industrialheating.com/connect Now it’s easier than ever to stay connected to the best source of news in the industry!

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Doug Glenn Publisher • 412-306-4351 [email protected] EDITORIAL/PRODUCTION STAFF Reed Miller Associate Publisher/Editor–M.S. Met. Eng., [email protected] • 412-306-4360 Bill Mayer Associate Editor, [email protected] • 412-306-4350 R. Barry Ashby Washington Editor Dan Herring Contributing Technical Editor Dean Peters Contributing Editor Beth McClelland Production Manager, [email protected] • 412-306-4354 Brent Miller Art Director, [email protected] • 412-306-4356 AUDIENCE DEVELOPMENT Christina Gietzen Audience Development Coordinator Alison Illes Multimedia Specialist Catherine M. Ronan Corporate Audience Audit Mgr. For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected] LIST RENTAL Postal contact: Rob Liska at 800-223-2194 x726 [email protected] Email contact: Shawn Kingston at 800-409-4443828; [email protected]

12 June 2011 - IndustrialHeating.com

ADVERTISING SALES REPRESENTATIVES Kathy Pisano Advertising Director, [email protected] Ph: 412-306-4357 • Fax: 412-531-3375 Becky McClelland Classified Advertising Mgr., [email protected] • 412-306-4355 Larry Pullman Eastern & West Coast Sales Mgr. 317 Birch Laurel, Woodstock, GA 30188 Toll free: 1-888-494-8480 or 678-494-8480 Fax: 888-494-8481 • [email protected] Steve Roth Midwest Sales Mgr., (520) 742-0175 Fax: 847-256-3042 • [email protected] Patrick Connolly European Sales Representative Patco Media - London, 99 Kings Road, Westcliff, Essex (UK) SSO 8PH, (44) 1-702-477341; Fax: (44) 1-702-477559 [email protected] Mr. V. Shivkumar India Sales Representative, [email protected] Mr. Arlen LUO Newsteel Media, China; Tel: 0086-10-8857-9899; Fax: 0086-10-8216-0061; [email protected] Becky McClelland Reprint Quotes, 412-306-4355 Susan Heinauer Online Advertising Manager, [email protected] • 412-306-4352

CORPORATE DIRECTORS Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Information Technology: Scott Kesler Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec BNP Media Helps People Succeed in Business with Superior Information

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Editorial Reed Miller, Associate Publisher/Editor | 412-306-4360 | [email protected]

CO2-Reduction Contrarian

I

t seems I am often the contrarian when it comes to environmental issues. My current position and quarter-century career in this industry have certainly helped form ideas that may be in opposition to the status quo. I’ll call the “status quo” what we see and hear on the national news stage. Let’s review the status quo to see how adherence to it might affect those of us in the thermal-processing world. What we experience tends to affect how we think about an issue. The climate is something that all of us experience. It’s interesting that when recent tornadoes struck in the U.S., it was the result of global warming (GW) or climate change, but when we experienced one of the coldest winters of the past decade – it was the coldest March globally since 1994 – it is also GW’s fault. I read something recently in the Boston Herald that said, “For a theory to be scientific, it must be fallible – capable of being proven false. If every weather condition can be used to ‘prove’ GW simply by being declared ‘weird,’ then it’s not science. It’s a joke.” A Wall Street Journal (WSJ) article discussed The Twentieth Century Reanalysis Project, which is the latest attempt to find out whether recent weather trends are extreme by historic standards. Published this year, the project’s findings show no evidence of an intensifying weather trend. The climate models, which led the United Nations to predict that there would be 50 million “climate refugees” by 2010 (fail), indicate more and more extreme weather will occur as CO2 levels increase. An analyst with this project said, “We were surprised that none of the three major indices of climate variability that we used show a trend going back to 1871.” These researchers from the University of Colorado added, “There’s no data-driven answer yet to the question of how human activity has affected extreme weather.” Forecasts from prognosticators with no GW agenda, such as Piers Corbyn and Joe Bastardi, seem to have greater accuracy than those from the status-quo forecasters. Corbyn, who uses data such as the flow of particles from the sun to make his predictions, predicted London’s severe winter weather while the government’s Met Office predicted a mild winter in keeping with the GW narrative. Corbyn believes that the cold winters of the past three years are the harbinger of a mini ice age that could be upon us by 2035. He says that it could be colder than at any time in the past 200 years. Ironically, some of this winter’s extremes were magnified by the GW narrative, not by GW. The London-based Global Warming Policy Foundation charges that British authorities are so committed to the notion that Britain’s future will be warmer that they failed to plan for the winter storms of the last three years. It was 14 June 2011 - IndustrialHeating.com

also reported that the floods in Australia were similarly magnified in proportion because, using the narrative and fearing drought, officials would not allow any water to be released from dams and levies. The WSJ asserts, “Global-warming alarmists insist that economic activity is the problem, when the available evidence shows it to be part of the solution. We may not be able to do anything about the weather, extreme or otherwise, but we can make sure we have the resources to deal with it when it comes.”

“There’s no data-driven answer yet to the question of how human activity has affected extreme weather.” Why do we discuss this topic in an energy-conservation issue? Because energy conservation – a good thing – is often tied to the environmental (green) movement. Some of the goals of the environmental movement could decimate our industry and kill the U.S. economy. The WSJ indicated that even labor unions have joined the fight against the current administration’s environmental agenda. In a letter late last year, the United Steelworkers said that “tens of thousands” of jobs at factories whose employees are represented by the Steelworkers “will be imperiled” by EPA decisions. The miners’ union said the (EPA) proposal “could put at risk as many as 250,000 jobs.” A recent online piece helped me to realize why the steel industry is seeing this issue more clearly while the aluminum industry continues to support carbon cap-and-trade legislation. Agmetalminer.com reasoned that “aluminum, as a global industry, has a strategic advantage over the [largely] domestic steel industry. Climate-change legislation would handicap the steel industry while allowing the aluminum industry to leverage global supply options not subject to such legislation.” Interesting, and it’s an example of how policymakers need to think about future climate legislation/regulation. IH

Reed Miller, Editor

Use this Mobile Tag to view a pdf listing 55 benefits of increasing CO2. No smart phone? Use this URL: http://tinyurl.com/3dza4vb

Federal Triangle Barry Ashby, Washington Editor | 202-255-0197 | [email protected]

Debt, Deficit and Spending – A Financial Outlook

T

h elections last autumn showed that voters see accrued he federal debt, deficit reduction and spending as a major f national concern. n In fiscal year 2011, Washington will spend $1.65 trillion more than revenues. Economist and author Walter Williams recently wrote with despair and lamented both public ignorance and willful deception by both the news media and politicians fostering lies about this subject. Remember that Article 1, Section 7 of the Constitution specifies that “All bills for raising revenue shall originate in the House of Representatives; but the Senate may propose or concur with amendments as on other Bills.” The President of this nation has zero, zilch, zip, nada authority to raise or lower taxes. There were never any “Reagan deficits,” “Clinton surpluses,” “Bush tax cuts” or “Obama tax increases.” Congress alone, and the House of Representatives solely, is (and always has been) responsible for our now desperate financial mess. Congress can do anything it wants to regarding budgets and spending. There is no 60% of the federal budget that is off limits. There are no federal “investments” for “entitlement payments.” Government cannot create jobs. What government does is spend the people’s money as authorized and appropriated by Congress. Congressional weasels of both parties are liars when they claim anything other than these truths. Both party’s Presidents make demagogic comments to claim glory or avoid blame but, in doing so, are self-serving. Maybe this sets the stage for the topic I suggest you consider: Let’s make it personal. American families each owe about $700,000 for all government, private and corporate debt. So, debt service (annual interest) alone is about $56,000. (The $14.3 trillion total federal debt is composed of $9.7 trillion publicly owned plus $4.6 trillion intergovernmental debt. This divided among 300 million people is $48,000 per capita.) Interest needs are based on using Producer Price Index inflation rates of 5.5% and adding a risk premium of 2.5% to total 8%, and the result is about the national, per family, total income. Just to pay interest on this debt consumes all U.S. personal income. Recall that this is real debt today. It does not include implicit debt, “unfunded obligations,” to cover future commitments such as Medicare, Medicaid or federal pensions. All implicit federal debt is estimated to add $119.5 trillion more to the current debt load, but this estimate is based on the assumption that interest rates 16 June 2011 - IndustrialHeating.com

will stay at current levels of 2.2% whereas the historical average over the past two decades has been 5.7%. This obligation is important as there are zero assets for collateral in borrowing, unless you want to consider selling 80% of western U.S. federal lands to get out from under. In order to make the debt situation more tolerable to the public, which essentially has no clue about coming fiscal calamities, the Federal Reserve Bank has printed money and issued increasingly less valuable bonds. This is termed “quantitative easing.” There is a 90% probability that at the end of June, the Fed will initiate a third round of this exercise in currency devaluation to monetize the debt. This means that your government prints money and/or bonds to pay interest on the debt. In actuality, dollars have depreciated about 50% against sound world currencies over the past two years. Remember, I told you that Congressional weasels are liars. Now you can add Federal Reserve and Treasury management to that list. All of these matters are quite important to Americans and will have significant impacts on both U.S. individuals and industry. In late April, China’s finance minister made public comments recommending that U.S. bond holdings be reduced from $3.04 trillion to about $1 trillion. This says that the largest U.S. debt holder is losing confidence in the dollar. Concurrently, Standard & Poor’s downgraded U.S. bond quality from stable to negative. With actual U.S. inflation already over 10%, regardless of federal spin that the public distrusts more and more, world confidence in the dollar wanes. It is evident that dollars as the reserve currency for the world is being questioned. (Transactions between countries have been denominated in dollars since World War II when the pound sterling and Europe’s economy suffered and was replaced by the dollar.) Reserve currency replacement has not been identified, but the dollar is not on the short list. There are other indicators such as the fact that almost half of world consumers buy oil with a new “basket currency,” not dollars. This is a topic still being defined. Oil purchases are no longer in dollars only. While U.S. political liberals say that “debt is only money we owe ourselves,” that is wrong if the rest of the world owns some of our debt and walks away with an expression of no confidence. Readers of this journal should be prepared in six to 12 months to face: high (even hyper) inflation, energy costs of two to fourfold increase, problems in bank lending (none) compared to today and continued outflow of industrial production to more hospitable venues. IH

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Martensite artensite is our friend,” so sayeth the heat treater, but what is martensite, really? And why is a tempered martensitic structure the single-minded goal of every heat treater when hardening steel? Let’s learn more.

Martensite Formation In order to form martensite we need to heat steel into the austenite field (above Ac3) and quench rapidly enough from the austenite phase to avoid pearlite formation. The rate must be fast enough to avoid the nose of the Time-Temperature-Transformation (TTT) curve – the so-called critical cooling rate for the given steel. The formation of martensite involves the structural rearrangement (by shear displacement) of the atoms from face-centered cubic (FCC) austenite into a body-centered tetragonal (BCT) martensitic structure. This change is accompanied by a large increase in volume and results in a highly stressed condition. This is why martensite has a higher hardness than austenite for the exact same chemistry. The martensite transformation, while not instantaneous, is significantly faster than diffusion-controlled processes such as ferrite and pearlite formation that have different chemical compositions than the austenite from which they came. Thus, martensite is a meta-stable, strain-induced state that steel finds itself in. The resultant steel hardness is (primarily) a function of its carbon content (Fig. 1).

lath and plate types. As the carbon content increases, so-called high-carbon martensite twins begin to replace dislocations within the plates. This transformation is accompanied by the volumetric expansion mentioned earlier, creating (residual) stress in addition to the strains due to interstitial solute atoms. At high carbon levels these stresses can become so severe that the material cracks during transformation when a growing plate impinges on an existing plate.[3] Thus, coarse martensite (Fig. 5) and plate martensite are less desirable structures in most applications. Ms and Mf Temperatures The martensite transformation begins at the martensite start (Ms) temperature and ends at the martensite finish (Mf) temperature and is influenced by carbon content. Increasing the carbon content of the austenite depresses the Ms and Mf temperatures, which leads to difficulties in converting all of the austenite to martensite. Ms and Mf temperatures are also important in welding, as they influence the residual stress state.[5] Ms and Mf temperatures can be calculated, and if you need to know them for a particular steel, one source for this data is at www.thomas-sourmail.org/martensite.html, which lists over 1,000 different steel types. 68 900 65 800

18 June 2011 - IndustrialHeating.com

Hardness, DPH

700

Martensite Morphology Morphology is a term used by metallurgists to describe the study of the shape, size, texture and phase distribution of physical objects. Martensite can be observed in the microstructure of steel in two distinctly different forms – lath or plate – depending on the carbon content of the steel (Fig. 2). In general, lath martensite is associated with high toughness and ductility but low strength, while plate martensite structures are much higher in strength but tend to be more brittle and non-ductile.[2] For alloys containing less than approximately 0.60 wt.% carbon, lath martensite appears as long, thin plates often grouped in packets (Fig. 3). Plate (or lenticular) martensite is found in alloys containing greater than approximately 0.60 wt.% carbon. The microstructure is needle-like or plate-like in appearance across the complete austenite grain (Fig. 4). With carbon contents between 0.60 and 1.00 wt.% carbon, the martensite present is a mixture of

60

600

50

500

400

300

200

Marder (27) Hodge and Orehoski (28) Burns et al. (29) Irvine et al. (30) Kelly and Nutting (31) Kurjumov (32) Litwinchuk et al. (33) Bain and Paxton (34) Jaffe and Gordon (35) Materkowski (36)

40

30 20 10 0

100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 Carbon, wt %

Fig. 1. As-quenched hardness vs. carbon content[1]

Hardness, Rockwell C

M

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work

•

•

rial H

TH

Greninger (8) Toriano and Greninger (10) Cohen et al (24) Digges (25) Greninger and Troiano (26) Kaufman and Cohen (27) Esser et al (28) Bibby and Parr (29)

1400 Ms Temperature, ˚F

1200 1000 800

871

Table 1. Crystal structures formed in martensite or quasi-martensite transformations [6]

760

Alloy system

649

Co, Fe-Mn, Fe-Cr-Ni

FCC to HCP

Fe-Ni

FCC to BCC

538 427

600

316

400

204

200

93

Mixed

Lath

Plate

0 0

0.2

0.4

Temperature, ˚C

1600

0.6 0.8 1.0 Carbon, wt %

1.2

1.4

0 1.6

Fig. 2. Formation of lath and plate martensite[1]

Tempered Martensite All steels containing martensite should be tempered. As heat treaters, we need to know that martensite in steel produces a hard, brittle microstructure that must be tempered to provide the delicate balance necessary between strength and toughness needed to produce a useful engineering material. When martensite is tempered, it partially decomposes into ferrite and cementite. Tempered martensite is not as hard as just-quenched martensite, but it is much tougher and is finer-grained as well. Final Thoughts about Martensite The heat treater might be interested to know that martensite formation is not restricted just to steels because other alloy systems produce crystallographic changes of a similar nature (Table 1). Learning more about martensite is an essential part of what we need to do as heat treaters since it is one of the defining characteristics of our industry. IH

Crystal structure change[a]

Fe-C, Fe-Ni-C, Fe-Cr-C, Fe-Mn-C

FCC to BCT

In-Ti, Mn-Cu

FCC to BCT

Li, Zr, Ti, Ti-Mo, Ti-Mn

BCC to HCP

Cu-Zn, Cu-Sn

BCC to FCT

Cu-Al

BCC to HCP (distorted)

Au-Cd

BCC to Orthorhombic

ZrO2

Tetragonal to Monoclinic

Notes: [a] FCC = face-centered cubic; BCC = body-centered cubic; HCP = hexagonal close packed; BCT = body-centered tetragonal; FCT = face-centered tetragonal;

2. 3. 4. 5.

6. 7. 8.

Steel, D.V. Doane and J.S. Kirkaldy [Eds.], AIME, Warrendale, PA, 1978, pp. 229-248. Vander Voort, George F., “Martensite and Retained Austenite,” Industrial Heating, April 2009. Elements of Metallurgy and Engineering Alloys, F. C. Campbell [Ed.], ASM International, 2008, pp. 169 – 173. Vander Voort, George F., “Microstructures of Ferrous Alloys,” Industrial Heating, January 2001. Payares-Asprino, M. C., H Katsumot and S. Liu, “Effect of Martensite Start and Finish Temperature on Residual Stress Development in Structural Steel Welds,” Welding Journal, Vol. 87, November 2008. Zackary, V. F., M. W. Justusson and D. J. Schmatz, Strengthening Mechanisms in Solids, ASM International, 1962, p. 179. G. B. Olson and W. S. Owen [Eds.], Martensite, ASM International, 1992. Krauss, George, Steels Processing, Structure and Performance, ASM International, 2005.

Use this Mobile Tag to view the Vander Voort article on martensite and retained austenite

References 1. Krauss, G., “Martensitic Transformation, Structure and Properties in Hardenable Steels,” in Hardenability Concepts with Applications to

10μm Fig. 3. Lath martensite example (carburized 8620)[4]

20 June 2011 - IndustrialHeating.com

10μm Fig. 4. Plate martensite example (carburized 8620)[4]

Fig. 5. Coarse martensite (carburized SAE 9310)

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Environmental & Safety Issues Richard J. Martin | Martin Thermal Engineering, Inc. | 310-937-1424 | [email protected]

Solid-Waste Netherworlds “

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h more you explain it, the more I don’t understand it.” he Mark Twain certainly would have had a field day comM menting on today’s complex world of environmental m regulations. r Throughout most of human history, the term “solid waste” had a simple definition – a material that is neither liquid nor gas that is no longer useful and is ready to be discarded. Alas, with the help of the U.S. Environmental Protection Agency (EPA), the concept of solid waste is no longer simple. In fact, the EPA has created at least nine different web-based resources to help explain the what, how and why of solid waste to the regulated community. Incoherent Regulations In the words of James Madison, “It will be of little avail to the people … if the laws be so voluminous that they cannot be read or so incoherent that they cannot be understood.” One particularly incoherent aspect of our environmental regulations is that the term “solid waste” is both a super-category and a sub-category. The super-category is where non-hazardous wastes are distinguished from hazardous substances. At this level, the definition of solid waste is actually quite sensible, incorporating municipal solid waste (e.g., garbage and trash) and industrial solid waste (e.g., production scrap and demolition waste) in the non-hazardous category. Unfortunately, the common sense ends there. Because hazardous substances have the potential to become hazardous wastes, the EPA seems to have reasoned that “solid waste” should also be a sub-category under hazardous substances. In this realm, physics takes a back seat to chutzpah because gases and liquids suddenly become candidates for designation as solid wastes. “Definition” Regulations Novices who wish to venture into the regulatory world of solid waste are directed to the EPA’s “DSW Tool” webpage, which provides an interactive guide through the “Definition of Solid Waste” regulations. Yes, you heard it right. Our nation is blessed with an entire set of regulations that define what constitutes a solid waste! Gone are the days when definitions comprised a page or two at the beginning of a regulation. Now they comprise an entire regulation unto themselves. The DSW Tool is essentially a decision tree that helps users discover the true identity of their solid waste by sending it through a set of decision gates that ultimately lead to the following (mutually exclusive) netherworlds: “Solid Waste,” “Not a Solid Waste,” 22 June 2011 - IndustrialHeating.com

“Non-Hazardous Waste,” “Excluded Material/Process” and “Solid Waste, even when Used/Re-used.” Compendium To further assist the public, the EPA published a set of 23 documents (398 pages total) called the Definition of Solid Waste Compendium. The preamble contains the following confession: “A frequently mentioned comment from stakeholders is the need for EPA to improve the user-friendliness of the existing regulations … stakeholders have difficulty understanding the regulations and identifying solid waste.” Are we surprised that stakeholders are confused when the EPA expects the regulated community to adopt and appreciate concepts such as: Inherently Waste-Like Materials (which means chemical by-products that often contain dioxins), Use Constituting Disposal (meaning materials used to make cement, fertilizer and anti-skid agents) and Universal Wastes (which applies “universally” to a few types of batteries, pesticides, thermostats and lamps)?

The EPA has created at least nine different webbased resources to help explain the what, how and why of solid waste to the regulated community.

Oxymoron Delving a bit deeper into the seemingly oxymoronic category “Solid Waste, even when Used/Re-used,” we find that some materials are solid wastes even if they are recycled, used, re-used or returned to the original process. This includes materials that are burned for energy recovery or used to produce a fuel. Thus, while one branch of regulators wants to encourage conservation of energy (ostensibly to reduce emissions of greenhouse gases), another branch wants to micro-manage how industry goes about doing it. As Benjamin Franklin put it, “Only a virtuous people are capable of freedom. As nations become more corrupt and vicious, they have more need of masters.” In the realm where industry intersects with the environment, today’s master is the regulator. One way for industry to liberate itself from this exasperating ruler would be to develop a market-based system to handle the disposition of all forms of waste material – gas, liquid and solid. Since generating and discarding waste material causes varying degrees of negative consequences to neighboring businesses and individuals, the system would have to account for those negative impacts in a manner commensurate with the potential damage. This columnist welcomes reader input on the subject and hopes to assemble a future column enumerating promising ideas. IH

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Metallurgical High Vacuum Corporation Excellence since 1981

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e etallurgical High Vacuum Corporation (MHV) is a vital supplier in the vacuum technology industry. t With over 30 years in the business, the company has earned a reputation for responsiveness p with high-quality engineering and manufacturing. Customers depend on MHV for keeping their operations running and keeping their costs under control. Technology History MHV was founded in Holland, Mich., in 1981 by Geoff Humberstone as a consulting business, delivering engineering expertise to the high-vacuum industry. The business was expanded in 1985 to provide in-depth service, design and engineering on a wide range of high-vacuum equipment, including quality remanufacturing of vacuum, booster and diffusion pumps and blowers. With the addition of in-house, computer-controlled, worldclass MAZAK computerized machining center, fabrication/welding facilities and CAD/CAM capabilities, MHV today is a supplier of pumps and complete vacuum process systems including specialized chambers, accessories and pumping systems. The Difference is Quality With a growing reputation for high-quality work and creative problem solving, the company outgrew its 5,000-square-foot plant in Douglas, Mich. It currently occupies a 16,000-square-foot facility, built in 1996, on a 17-acre site near Fennville, Mich. This plant features an 80-foot x 200-foot open bay with a 30-foot-high ceiling and 10-ton overhead crane. A 30-foot x 60-foot building was added in 1998 to warehouse cores and fixtures. A new 2,400-square-foot business office and engineering center was completed in 2006, equipped with the latest 3-D CAD system. The professional staff of 12 includes metallurgists, engineers, administrative staff and factory-trained machinists and technicians. MHV is able to manufacture new vacuum equipment and

systems; remanufacture and refurbish most brands and models of vacuum pumps; and reverse-engineer and manufacture many hard-to-get components. The company has the facilities and staff to perform all the machining, welding, rebuilding, refurbishment and integration on-site. As a result, MHV can tightly control all the manufacturing operations for quality and scheduling. MHV’s products and services include: vacuum chambers, piping and manifolds, flexible connectors, accessories, vacuum valves, custom oil filtration systems, helium leak testing, field installation, training and repair. Extensive testing capabilities include leak checking and hot testing for every pump to ensure performance with documented results as proof of quality. The key to MHV’s quality is its ability to understand and solve vacuum-processing problems for customers coupled with outstanding technical support. Length of Service is Vital Vacuum pumps are often used in tough applications like sintering of powdered metals, brazing and coating. Such processes develop water vapor, acids or small particles that can contaminate and shorten pump service life. MHV has responded to this by developing oil filtration systems that can significantly reduce contamination, double or triple service life, and provide better return on the customer’s investment. Future Goals President Geoff Humberstone said, “We want to help our customers keep their production operations running by delivering their products and controlling their long-term costs. What helped us to grow over the years is a solid reputation for high-quality work, creative engineering and a ‘can do’ attitude for customer service. We will not settle for anything less now and in the future.” For more information on MHV, visit www.methivac.com, e-mail sales@met hivac.com or call 269-543-4291.

Metallurgical High Vacuum Corporation’s facility in Fennville, Mich. (Right) MHV 430-CFM vacuum pumps built for a customer’s application requiring high pumping speed in a compact package. Dual oil filters are designed to trap oil contaminants for longer pump life.

24 June 2011 - IndustrialHeating.com

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IHEA Announces 2011-12 Officers, Board

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h Industrial Heating Equipment Association (IHEA) he announced its 2011-12 officers and Board of Directors at a its recent Annual Meeting. i Bill Pasley of Southern Company will serve as IHEA’s 2011-12 president. Pasley said, “We are building upon 82 years of industry leadership, and we are now expanding on this firm foundation. There is an unprecedented opportunity to establish IHEA as the entity wherein all manufacturers of process-heating equipment and associated service providers can work together for the benefit of the industry.” Mike Shay of Elster Kromschröder was named first vice president; Tim Lee of Maxon, A Honeywell Company was elected treasurer; and Lach Perks of Eclipse assumes the role of past president. The following members will serve on IHEA’s 2011-2012 Board of Directors: • Keith Boeckenhauer (SECO/WARWICK) • David Bovenizer (Selas Heat Technology Co.) • Mike Chapman (Vulcan Catalytic Systems) • Jay Cherry (Wellman Furnaces) • Doug Glenn, (Industrial Heating magazine) • Bob Green (Bloom Engineering)

Incoming President Bill Pasley (left) accepts the IHEA President’s gavel from outgoing Past President Max Hoetzl.

• Max Hoetzl (Surface Combustion) • Scott Kinney (Rolled Alloys) In an address to IHEA members, Pasley said, “Increasingly rapid movement in trends related to globalization, energy usage, manufacturing complexity, and the environment is helping to highlight the value of the framework IHEA is providing to the industry. Through recognized industry leaders, our association is focusing more than ever on assuring that process-heating issues are properly addressed by regulators, legislators and other government entities such as the Department of Energy and the EPA. We continue to be this industry’s leader in the areas of safety, standards and training, and we will expand this effort in 2011-12.” IHEA Fall Schedule Fall brings the return of IHEA’s 42nd Annual Combustion Seminar and its popular Online Process Heating Distance Learning Courses. The Omni William Penn in Pittsburgh, Pa., will host the Combustion Seminar and Tabletop Exhibition on Sept. 27-28. This two-day event consists of 16 educational sessions that will discuss topics including air-gas premixing, burners, controls, flame supervision, gas-flow measurement, metering, NOx and more. The tabletop exhibition gives attendees an opportunity to speak with company representatives and learn more about the products and services discussed in the classroom environment. IHEA’s Fall Business Conference will follow the Combustion Seminar at the Omni William Penn on Sept. 28-29. Registration for IHEA’s Online Process Heating Distance Learning Courses will open July 18 and will close Sept. 9. The two classes offered, “Fundamentals of Industrial Process Heating” and “Advanced Industrial Process Heating,” begin Sept. 19 and run through Nov. 4 (Fundamentals) and Dec. 2 (Advanced). In the instructor-led, interactive online course, you will learn safe, efficient operation of industrial heating equipment, how to reduce energy consumption and ways to improve your bottom line.

CECOF General Secretary Retires Dr. Gutmann Habig has retired as general secretary of CECOF, a position he held since 1992. Dr. Habig was a frequent presence at IHEA Annual Meetings since 1998. He said, “What particularly impressed me is the strong engagement and commitment of company members and executives to take on association jobs on the board and on the committees. I envy IHEA having such a solid dedication from individual members.” CECOF (the European Committee of Industrial Furnace and Heating Equipment Associations) is the respected voice and lobby organization of the thermal-processing industry in Europe. It incorporates almost all relevant European manufacturers of this kind of equipment. CECOF represents its members’ interests in economic and technical issues.

26 June 2011 - IndustrialHeating.com

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The Experts Speak: Blogs in Print George Vander Voort | 847-623-7648 | [email protected]

Picric Acid Hazards and Safe Usage

onth Friend of the M

P

iicric acid (2,4,6-trinitrophenol, [(NO2)3C6H2OH]) is widely used in metallography labs for the very common etchants known as picral – a 4% m solution in ethanol developed by Igevski – and in Vilella’s reagent – 1% picric s acid and 4% HCl in ethanol developed by Jose Ramon Vilella (1938) – as a well as several other formulations. Picric acid was formulated by British chemist Peter Woulfe in 1771 although Glauber is claimed to have written about it in 1742. The name comes from the Greek word pikros, which means bitter, as picric acid has a bitter taste. It was initially used to dye fabrics yellow. In the early 20th century, workers producing picric acid were sometimes called canaries, because their skin also became stained yellow. The explosive nature of picric acid was discovered in 1885 in England, which led to the development of an explosive called Lyddite in 1888, named after the location of the studies in Lydd, England. Anhydrous picric acid is related to TNT, a much more potent explosive. In its concentrated form, it will attack metals, producing shock-sensitive, explosive salts. This was discovered in 1916 at a French ammunition factory when a fire caused molten picric acid to wet a concrete floor, which formed calcium picrate that detonated killing 170 people. Fortunately, there have been no documented cases of explosions from picric acid in laboratories, according to Phifer.[1] The concern has always been in finding an old bottle that has dried up producing dehydrated picric acid and if it has a metal cap rather than a plastic cap. In such a case, the shock-sensitive metallic picrates may have formed at the cap-bottle interface. The solution is to have a robot pick it up and re-hydrate the picric acid after opening the bottle under water. If the cap is plastic and the acid has dried out, friction from opening the cap could cause detonation. The solution here is to place the bottle in a large bucket or tank of water and allow water to dissolve any dried picric acid on the cap threads. Leave the bottle in the water for a few days until some water can be seen inside the bottle. Then, open the lid and re-hydrate the picric acid. Obviously, the wise lab manager checks the picric acid bottle periodically (which can vary with lab usage of picric in etchants) to make sure that the picric acid remains wet. Today, bottles are sold with at least 30% water. Clean the cap and threads on the bottle and on the cap with a wet paper towel. If you have copper piping, do not dispose of picric acid by pouring it down the drain as explosive metallic salts could form. Virtually all chemicals and solvents used in the laboratory are dangerous. Hence, we must develop good safe laboratory practices and teach our employees what to do to avoid problems. Personally, I have never heard of a problem in a metallography/materialography laboratory from picric acid. But I know of four accidents from nital (2-3% nitric acid in ethanol), which people consider to be very safe to use. Every dangerous chemical or solvent cannot be outlawed for use, or we will not be able to work. The solution is to establish a good laboratory safety program and train employees and develop safe working habits. References 2-4 summarize lab safety aspects as a sequel to the superb treatise by Anderson.[5] ASTM E 2014 lists a number of books on laboratory safety and is a good source of information on metallography lab safety. IH See www.industrialheating.com/gvv for the references and the full blog from Vander Voort.

28 June 2011 - IndustrialHeating.com

T i m Centa

Facility Engineering Manager – Goodrich Aerospace

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im oversees maintenance, facility and project engineering for the Goodrich aircraft wheel brake manufacturing location in Pueblo, Colo. The facility, which produces carbon/carbon brakes, operates high-temperature induction furnaces for chemical vapor deposition and heat treatment of carbon composite materials. College: 1. Colorado School of Mines 2. Colorado State University - Pueblo Degree: 1. Chemical Engineering in 1997 2. MBA in 2006 Marital Status: Married with three kids 4, 3 & 1 years old Activities: Snowboarding, mountain biking, camping & hiking IH Reader: Tim's been reading Industrial Heating for 7 years.

Industry News

Equipment News Box Furnace Lucifer Furnaces designed a large heat-treating box furnace for a manufacturer in the aerospace industry. The 20-inch-high x 20-inch-wide x 40-inch-long unit will be used in the production of engine parts. This three-zone furnace with tight uniformity meets the AMS 2750 specification required by Nadcap. The new furnace, which heats to 2000°F, will complement an existing one already in operation. The company chose this equipment with the goal of shortening heat-treating cycles. With a three-zone master/slave temperature control system and overtemperature safety controls linked to a computer interface, reduced cooling time is achieved through a fresh-air damper system. Fifty-four kW of power is generated through heavy-gauge wire heating elements in removable radiant panels located in the door as well as side walls and rear wall of the furnace. The horizontal swing door is secured with two cam locks and a safety micro switch to automatically shut power when the door is opened. www.luciferfurnaces.com

Nitrocarburizing Systems Nitrex Metal completed Phase 2 of a four-phase nitrocarburizing project for Chinese industrial gear maker Nanjing High Speed & Accurate Gear Co. (NGC). Nitrex’s scope of supply includes multiple nitrocarburizing systems based on a common horizontal-loading chamber furnace platform. Phase 3 will be fully completed in 2011. Nitrex’s involvement is in the front-end engineering phase of the project, including system and process control design, licensing of

Nitreg®-C nitrocarburizing technology, and on-site operation and testing of the systems. www.nitrex.com

Walking-Beam Furnace BTU International announced the receipt of orders for nuclear fuel sintering equipment. The total value of the orders, consisting of a walking-beam furnace and parts, approaches $3.5 million. The units will be shipped this year to customers located in Asia. BTU’s walking-beam furnace is a hightemperature system designed for handling heavy loads under precisely controlled temperatures and atmospheric conditions. Various system configurations provide process temperatures up to 1800°C and atmosphere capabilities from oxidizing to fully reducing. The walking-beam system includes a number of BTU’s proprietary technologies, including variable density refractory components, eductor technology and the walkingbeam mechanism. www.btu.com

TriOx

Ultra Low NOx Emissions of 20 ppm or Less

Triple-Air Staged Ultra Low NOx Burner Visit Hauck at ThermProcess 2011 Hall 09/D22

• Direct spark or pilot ignition • Ambient or pre-heated air • Low excess air operation (5%) for maximum fuel efficiency • Proven benefit of scale and dross reduction in steel and aluminum applications • Low CO emissions on cold start

Hauck’s TriOx burner is ideally suited for aluminum furnaces, steel reheat furnaces, thermal fluid heaters, and other high temperature heat processes requiring ultra low NOx emissions. Capacities range from 4.2 to more than 27 MM Btu/hr (1380 to 8960 kW) with five sizes and 4 models to choose from. ®

Hauck Manufacturing Company, PO Box 90, Lebanon, PA 17042 Phone: 717-272-3051 Fax: 717-273-9882

30 June 2011 - IndustrialHeating.com

www.hauckburner.com

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Industry News

Vacuum Furnace

Spark Plasma Sintering System

VAC AERO International sold a vacuum furnace to Samsung Electrics to be used for hardening captive press and plastic die molds used in the manufacture of mobile phones, refrigerators and washing machines. The furnace will be housed in Samsung’s new stateof-the-art facility in Gwangju Metropolitan City, Korea. The VAH6660 HV-6 is equipped with VAC AERO’s Honeywell HC900 interactive control system with complete network integration capabilities and remote monitoring and control. The hot zone measures 48 inches wide x 48 inches high x 60 inches deep and is comprised of high-efficiency graphite felt, carbon composite and curved graphite elements. The furnace operates at temperatures up to 2400°F. The vacuum pumping system includes a diffusion pump for high-vacuum applications to 10-5 Torr. Delivery is scheduled for this summer. www.vacaero.com

Thermal Technology shipped a spark plasma sintering (SPS) system to a leading Russian research institute. The SPS Model 10-3 provides 10 tons of force and a 3,000-amp power supply. Thermal Technology’s SPS systems are designed with highly rigid fourpost press frames, an extra-large working chamber and large access doors. The flexible footprint accommodates users’ spatial limitations, while the advanced power supply provides unequaled adjustability and heat rates greater than 1500°C per minute. Digital servo valve-controlled hydraulics ensure ultra-fine force control, while programming and data acquisition are accomplished using an on or off-line PC system. syste www.thermal technology.com

Walking-Beam Furnace Tenova Core has been contracted by Gerdau Ameristeel to design and supply a 140-ton/hour walking-beam reheat furnace. The furnace will be installed at Gerdau’s Calvert City, Ky., facility in 2012. It will replace an existing furnace and will be used to efficiently and uniformly heat billets for processing. The furnace will feature a combustion system equipped with Tenova’s TSX low-NOx recuperative burners for reliable temperature uniformity as well as emissions control. Tenova Core will also design and supply the Level 1 and Level 2 process control and automation systems for the furnace. This project will mark the first installation on a new furnace of Tenova Core’s Level 2 system that includes an advanced model predictive control engine. The new Level 2 system heats the charge at an “optimum cycle” predetermined for each type of material for the complete range of furnace production rates. www.tenovacore.com

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32 June 2011 - IndustrialHeating.com

Francis Bacon,1561–1626 1st Viscount Saint Alban

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Industry News

Business News Lakeside Steel to Expand New Facility

Lakeside Steel plans to expand its previously announced $7.5 million tubular end-finishing and heat-treatment facility in Thomasville, Ala., to add end-finishing and heat-treatment processing capabilities for casing products. The company will expand the new end-finishing facility, at an additional capital cost of approximately $10 million, to enable Lakeside to end finish and heat treat casing products in addition to the previously announced tubular-product finishing capabilities. The expansion will enable Lakeside Steel to upgrade casing to high value-added products including L80, N80 and P110 products used in the most demanding onshore drilling applications in North America. The facility will be capable of processing 4.5-inch-diameter to 5.5-inch-diameter casing pipe, with a capacity of up to 100,000 tons per year. When in operation, Lakeside Steel expects that the expansion will employ approximately 80 people, bringing total employment of the end-finishing and heat-treatment facility to around 160 people.

TMK Ipsco Breaks Ground on R&D Center TMK Ipsco broke ground on a new 51,000-square-foot research and development center in Houston, Texas. The state-of-the-art facility will serve as the heart of the company’s innovation initiatives – new product design and development, experimental and validation testing, and advanced metallurgical research. It will serve TMK Ipsco as well as the global operations of its parent company, Moscow-based OAO TMK. The R&D center, which is scheduled to open in the fall of 2011, will bring in-house much of the analysis, modeling and testing work that is currently performed by outside providers. The building will feature a high bay testing area, a variety of support laboratories and 27,000 square feet of office space. Two high-tech connection testers rated at 4 million pounds and 2 million pounds of tension, respectively, will be among the key

pieces of equipment installed at the new research center. Other key equipment will include a scanning electron microscope, a collapse tester, tensile and fatigue testers, and a corrosion testing lab.

California Company Adds Manufacturing Facility BendPak of Santa Paula, Calif., started construction on a new $65 million facility. It will be used primarily for manufacturing certain light and medium-duty lift products and select parking systems. The 480,000-square-foot plant will house stateof-the-art equipment including turning and milling equipment and automated welding systems as well as full-capability services like comprehensive metallurgy testing, heat treatment and automated powder coating. The facility will also include assembly and packaging operation centers and product development testing labs for BendPak’s growing customer base.

Materials | Development | Solutions

Creating Solutions for Future Heat Treat Technologies H.C. Starck offers value-added product solutions from molybdenum, tungsten, tantalum, and their alloys, La-doped molybdenum and TZM. These products are ideal for heat treating, sintering, annealing, brazing, and all high temperature furnace applications in the medical, aerospace, defense, and automotive industries. > Furnace Parts > Heat Shields > Sintering Boats

> Heating Element Materials > Tungsten & Molybdenum Mill Products

H.C. Starck has production facilities in Europe, America, and Asia to better service our customers.

[email protected] www.hcstarck.com

34 June 2011 - IndustrialHeating.com

Industry News

Republic Engineered Products Acquires BCS Assets Republic Engineered Products Inc., a subsidiary of Grupo Simec, acquired assets of BCS Industries consisting of a heat-treatment facility and cold-drawn steel bars. These facilities are located in Cleveland, Ohio, and Memphis, Tenn. With this acquisition, Republic enhances and complements its capacity production of special bars (SBQ).

Aluminum Processor to Open Facility in Indiana Huntington Aluminum will establish its initial operation in Huntington, Ind., creating up to 43 new jobs by 2013. The company plans to invest $1.1 million to purchase and equip a 58,000-squarefoot building. Huntington Aluminum will melt aluminum chips and resell them as ingots and sows. The company wants to begin hiring processing and supervisory associates this summer and anticipates being operational by July.

SCA Receives Certification Solar Atmospheres of California (SCA) announced the successful completion of AS9100/ISO 9001:2008 certification – the premium quality-system standard for companies operating in the aerospace industry. AS9100 encompasses the entire current version of ISO 9001 as well as specific requirements addressing well-known problems related to the aerospace sector. The audit was performed by International Standards Authority. Certification was awarded on April 11.

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Metallography of Welds

WeFR E bin E ar

June 29, 2pm EDT.

SPEAKER George Vander Voort, Metallurgical Engineer, Consulting, Struers Inc. George, a metallurgical engineer, has over 30 years of work experience in the specialty steel industry at Bethlehem Steel and Carpenter Technology and is currently a consultant for Struers Inc. George has authored two books, he has educated thousands through his 370 lectures in 39 countries, written 280+ publications and has taught 73 ASM courses.

Metallographic principles and practices can be applied to the examination of welded sections to satisfy a number of objectives i.e.: production testing, quality control, research and development, and of course, failure analysis. Metallographic examination is used to check many different aspects of a weld region such as the extent of stress to the heat affected zone (HAZ) and any defects such as porosity, fusion, tears and cracks of the representative work piece. Learn the importance of proper metallographic preparation and how to address the primary challenges of preparing weld microsections for microscopic observation using real-life examples and demonstrations. George Vander Voort provides a thorough introduction and overview of welds in the manufacturing process. Learn to examine critical material performance information in control and verification of materials, processes and quality control.

DURING THIS WEB SEMINAR, WE WILL REVIEW AND EXAMINE THE FOLLOWING: • Difficulties encountered during metallographic preparation, using practical examples

MODERATOR

• Micro and macro level of metallographic inspection

Reed Miller, Editor

• Recommendations of metallographic practices applied to welded regions hear his responses live

Reed joined the Industrial Heating team in 2006 with 24 years of industry

Register for free at

experience. Throughout his career,

webinars.industrialheating.com.

Reed has worked with a variety of

Can’t attend live? You can watch on-demand at your convenience.

furnaces, from melting to tempering. He has a master’s degree in Metallurgy & Materials Science from Carnegie Mellon University.

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Industry Events

JUNE 20-22 Furnaces & Atmospheres for Today’s Technology; Meadville, Pa. www.secowarwick.com June 28-July 2 Thermprocess 2011 – International Trade Fair for Thermo-Process Technology; Düsseldorf, Germany www.thermprocess-online.com Industrial Heating is the Official North American Media Co-Sponsor

29 Free Webinar, hosted by Struers and Industrial Heating – “Metallography of Welds” www.industrialheating.com

AUGUST 18 Free Webinar, hosted by Industrial Heating – “Temperature Sensing/Control: The Right Tools Save You Money” www.industrialheating.com

SEPTEMBER

GET CONNECTED www.industrialheating.com/connect

12-15 Euromat 2011 – European Congress and Exhibition on Advanced Materials and Processes; Montpellier, France www.euromat2011.fems.eu 19-21 2011 Die Casting Congress & Tabletop; Columbus, Ohio www.diecasting.org/congress 20-22 Heat-Treatment 2011 – 5th International Specialized Exhibition; Moscow, Russia www.mirexpo.ru/eng

OCTOBER 11-13 Fundamentals of Brazing Seminar, hosted by Kay & Associates; Greenville, S.C. www.kaybrazing.com

N Now iit's ' easier i than h n ever eve verr to t sta stay y connec co connected nnectte nnec te to the best ted industry! ssource of news and d technology in the industr

The Retained Austenite Solution and More. Quench to freeze and back to temper with one profile. Eliminate multiple handling operations and increase product throughput.

16-21 MS&T 2011, in conjunction with ACerS 113th Annual Meeting; Columbus, Ohio www.matscitech.org 17-20 IFHTSE (International Federation for Heat Treatment and Surface Engineering) 19th Congress 2011; Glasgow, Scotland www.ifhtse2011.org Oct. 30-Nov. 4 AVS 58th International Symposium and Exhibition; Nashville, Tenn. www.avs.org Oct. 31-Nov. 2 ASM Heat Treating Society Conference and Exposition; Cincinnati, Ohio www.asminternational.org

NOVEMBER 10-12 Aluminium India 2011; Mumbai, India http://www.aluminium-india.com/ 11 Free Webinar, hosted by Industrial Heating – “Secrets of Hardness & Mechanical Testing” www.industrialheating.com

For over 15 years we have provided our customers maximum process flexibility and dependability with our complete line of combination furnace/ freezers with temperature ranges between +1200°F and –300°F. Full in house engineering and flexible manufacturing capabilities permit custom integration with existing lines.

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IndustrialHeating.com - June 2011 39

FEATURE | Industrial Gases/Combustion

Regenerative Burners or Oxy-Fuel Oxy Fuel Burners Regenerative Burners or Oxy-Fuel Burners for Your Furnace Upgrade? Jared S. Kaufman & Josh Marino – Tenova Core; Coraopolis, Pa. Recently, there has been significant interest in upgrading furnace combustion systems. The motivations range from increasing production to saving energy costs to reducing carbon dioxide emissions.

R

e egardless of the motive, the first step undertaken by a furnace operator is to investigate the various technolf ogies available. Two of the most intriguing technoloo gies are regenerative burners and oxy-fuel burners. g

Combustion Basics The most commonly used fuel combusted in furnace applications is natural gas, which is comprised of over 90% methane (CH4). Air, comprised of about 20% oxygen (O2) and the balance nitrogen (N2), is usually used as the oxidizer. Equation 1 expresses the typical combustion reaction, firing with 10% excess air. CH4 + 2.2 O2 + 8.27 N2A CO2 + 2H2O + 0.2 O2 + 8.27 N2

(1)

1 Fuel + 10.47 Air A 8.7% CO2 +17.4% H2O + 1.7% O2 + 72.1% N2 The hydrocarbon fuel chemically changes to a collection of exhaust gases: carbon dioxide (CO2) and water vapor (H2O). The N2 in the exhaust gas came directly from the combustion air. As shown, the process starts with chemical energy in the fuel. There is also some sensible energy in the oxidizer, proportional to its temperature. From this heat supply, process heat is used to heat the product as well as the various system losses (refractories, water, etc.). Finally, a significant amount of heat is carried out of the furnace in the form of sensible heat in the exhaust gases. This energy balance is summarized in equation 2.

is lost with the exhaust gas. Specifically, a media pulls heat out of the waste gases and temporarily stores it. The media is typically made up of ceramic balls or honeycombs. After the media is sufficiently heated, the combustion air is blown across it, thus pulling the heat out of the media and returning it to the combustion process. The net result is that the waste gases leave the process at a lower temperature, meaning that less energy is lost to the stack. In practice, regenerative burners usually work in pairs (Fig. 1). In this example, burner #1 is in firing mode while burner #2 is in exhausting mode. Burner #1 is firing with its combustion air blowing across the already hot burner #1 media, resulting in air preheat temperatures of about 300˚F less than the furnace-chamber temperature. Meanwhile, burner #2 is drawing the hot exhaust gases out of the furnace across the burner #2 media, heating up the media and cooling the exhaust gases. After a period of about 3060 seconds, the burners switch. The high air preheat temperature makes the combustion process very efficient because the flames do not have to heat the combustion air to the furnace operating temperature. A regenerative burner system involves the burners, ceramic media, media cases, switching valve, exhaust ductwork, and combustion air and exhaust blowers. The combustion reaction for normal 10% excess-air firing is exactly as presented in equation 1.

Chemical energy + Sensible heat – Sensible heat = Process heat (2) (Fuel) (Oxidizer) (Exhaust) (Useful heat)

Gas

Based on equation 2, we calculate the combustion efficiency as the useful process heat divided by the chemical energy in the fuel:

Burner #1

Closed Regenerative burner in fire mode

Furnace chamber Burner #2

Air

Efficiency = Process heat / Chemical energy in fuel

Air

(3)

Regenerative Burners Regenerative burners were designed with the idea of increasing the combustion efficiency by increasing the amount of sensible heat in the combustion air while reducing the sensible heat that

Flue gases

Flue gases Closed

Closed

Fig. 1. Regenerative burners IndustrialHeating.com - June 2011 41

FEATURE | Industrial Gases/Combustion

Oxy-Fuel Burners Another approach to increasing combustion efficiency is to fire specially designed burners with oxygen instead of air. The combustion efficiency is raised because of the fact that it takes about five times more energy to heat the air to the furnace operating temperature than the oxygen requires. This is because the air is comprised of almost 80% N2, which (for the most part) is not involved in the chemical reactions. An oxy-fuel burner system involves the specially designed burners, oxygen valves and piping. Unlike the regenerative burner case, the combustion equations are altered to account for the use of pure oxygen instead of air for the oxidizer. Operating with 10% excess oxygen, only 2.2 parts O2 are needed for every part CH4, as shown in equation 4.

Pressure Control Pressure control is essential to a furnace operation to ensure quality heating and energy efficiency. If regenerative or oxy-fuel burners are installed in addition to an existing combustion system, the exhaust-gas system will need to be expanded to handle the extra volume of combustion gases or else the furnace pressure will increase significantly. If these new burners are to be installed as replacements for existing burners, however, the impact on pressure control is not as simple. By their nature, the oxy-fuel burners release less waste gas, which may require downsizing the exhaust system so as to prevent a reduction in furnace pressure. On the other hand, replacing cold-air burners with regenerative burners requires a modification because the vast majority of furnace waste gases are exhausted through the burners, requiring some additional ductwork, valves and fans.

CH4 + 2.2 O2 A CO2 + 2H2O + 0.2 O2

Surface Oxidation Surface oxidation, or scale loss, is an inherent issue in product heating. It is dependent on residence time, surface temperature and furnace atmosphere. While the time and temperature aspects are dictated by the heating requirements of the product, the furnace atmosphere can vary widely depending on the furnace equipment and control. The typical components of a furnace atmosphere are categorized in Table 2. The rate of surface oxidation is dependent on the relative partial pressures (volumetric proportions) of these constituents. As equations 1 and 4 show, the percentages of oxidizing gases are significantly higher in the oxy-fuel burner case. This results in more scale loss, as shown in the heating-model analysis results in Fig. 3.

(4)

1 Fuel + 2.2 Oxygen A 31.3% CO2 + 62.5% H2O + 6.3% O2 Combustion Efficiency The combustion efficiency, or the percentage of available process heat over the chemical heat content of the fuel, was presented in equation 3. Table 1 shows a comparison of the combustion efficiency for a range of furnace temperatures. For comparison purposes, all cases were calculated based on natural gas firing with 10% excess air (or oxygen). As shown in the table above, the combustion efficiency for regenerative burners and oxy-fuel burners is almost identical. Each can provide significant energy savings over cold-air combustion systems and a proportional reduction in carbon dioxide (CO2) emissions. So, with almost identical performance in energy efficiency, the deciding factor shifts to other criteria. Process Heating One of the touted benefits of oxy-fuel burners is the improved process heating performance. The higher concentrations of triatomic molecules such as CO2 and H2O, as shown in equations 1 and 4, result in a higher emissivity, which increases the radiantheat transfer. On the other hand, the much larger flame envelope resultant from regenerative burners also increases the radiant-heat transfer to a slightly lesser extent than the oxy-fuel case. Sample heating model analysis results comparing the two are shown in Fig. 2. Table 1. Combustion efficiency as a function of furnace temperature Temperature

Emissions As with the other criteria, an evaluation of the emissions of oxyfuel and regenerative burner systems depends on the specifics of the project. Obviously, a furnace completely fired with oxy-fuel burners will emit practically zero NOx. This is because there is no N2 in the combustion reactions unless the furnace has air infiltration. Otherwise, if the oxy-fuel burners are installed in conjunction with air-fired burners, the NOx emissions will increase as the N2 already present in the furnace atmosphere (supplied through the air-fired burners) will form NOx in the oxy-fuel burner flames. With regenerative burners, higher air preheat results in higher flame temperatures, which then results in higher NOx emissions. Recent advancements in burner designs have contributed to reducing the NOx emissions from both oxy-fuel and regenerative burners. Table 2. Furnace-atmosphere constituents affecting surface oxidation

Cold air

Regenerative

Oxy-fuel

1600oF

53.0%

76.9%

77.7%

Oxidizers (form scale)

Reducers (reduce scale)

1800oF

47.6%

75.9%

75.8%

Oxygen (O2)

Carbon monoxide (CO)

2000oF

42.2%

74.8%

73.9%

2200oF

36.6%

73.8%

71.9%

Carbon dioxide (CO2)

Hydrogen (H2)

2400oF

30.9%

72.7%

70.0%

Water vapor (H2O)

Methane (CH4)

42 June 2011 - IndustrialHeating.com

2500

200% Analysis of 5.75" billet low carbon steel

180% 160%

1500 30 min - Oxyfired 30 min - Regen 60 min - Oxyfired 60 min - Regen 90 min - Oxyfired 90 min - Regen 120 min - Oxyfired 120 min - Regen

1000

500

0 1500

1700

1900 2100 Furnace temperature, ˚F

2300

2500

Fig. 2. Heating comparison

Capital Costs When comparing the capital costs associated with a combustionsystem upgrade, the regenerative burner system is typically more expensive to install. That is because it involves the burners, media and cases, piping, valves, ductwork and fans. The oxy-fuel system requires new burners, piping, valves and an oxygen-supply skid. Operating Costs One of the most common deciding factors in upgrading a combustion system is the resultant operating-cost impact. Typically, energy-saving projects are undertaken with the idea of paying for the project with natural gas savings. In the case of regenerative burners, this is clear. With oxy-fuel combustion, the verdict will depend on the oxygen-supply situation. Many plants operate with an oxygen contract with a gas supply company that provides “free” oxygen that would otherwise be unused. In this case, there is no additional operating cost for the oxygen. However, if the plant does not already have an oxygen contract, one must offset some of the natural gas savings with additional oxygen costs. Maintenance Costs The most significant drawback of regenerative burners is the additional maintenance costs. There are two sources of additional maintenance in the regenerative burner system. First, the media must be cleaned or replaced regularly because it picks up contaminants from the exhaust gas. The other maintenance items are the switching valves, whose actuators will fail after a certain number of cycles. An oxy-fuel combustion system will have minimal maintenance impact. Summary As this article demonstrates, oxy-fuel and regenerative burner combustion upgrade projects offer significant energy-savings possibilities. However, the decision as to which type of upgrade is best for a particular operation depends on numerous other factors, ranging from process considerations to cost structures. IH

Scale loss (% of baseline)

Discharge temperature, ˚F

2000

140% 120% 100% 80% 60%

30 min - Oxyfired 30 min - Regen 60 min - Oxyfired 60 min - Regen 90 min - Oxyfired 90 min - Regen 120 min - Oxyfired 120 min - Regen Analysis of 5.75" billet low carbon steel

40% 20% 0% 1500

1700

1900 2100 Furnace temperature, ˚F

2300

2500

Fig. 3. Surface oxidation comparison

For more information: Contact Jared S. Kaufman, P.E., VP of technical services, Tenova CORE, Cherrington Corporate Center, 100 Corporate Center Drive, Coraopolis, PA 15108; tel: 412262-2240; fax: 412-262-1308; e-mail: jkaufman@ tenovacore.com; web: www.tenovacore.com

Find regenerative burner suppliers in our online Buyers Guide.

Bill Bolt

Owner/President

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IndustrialHeating.com - June 2011 43

FEATURE | Heat Treating

Cut Costs and Stay Competitive with Advanced Energy Management Bob Zak – Powerit Solutions North America; Seattle, Wash. With the economy still challenging and competitive pressures continuing to rise, reducing expenses is imperative for industrial businesses. Yet many underestimate or neglect a key source of savings – the electricity bill.

Y

o may be wise to watching ou the th demand meter or shifting in heavy loads to off-peak hours, but those are not your h only options. With advanced energy-management technology, you can automate control of energy use so that your facility runs at optimal efficiency, you pay the lowest possible rates, and you can participate in incentive programs that pay you for unused kilowatts. Even the most energy-intensive businesses can cut energy costs without compromising production or quality. The key is to take full advantage of the load-shedding strategies that an advanced energy-management system enables: demand control, demand response, dynamic pricing optimization and energy efficiency (Fig. 1). Energy Cost-Reduction Strategies in Brief Demand Control

Demand control is a strategy that allows almost all industrial facilities to use energy more efficiently by managing peaks and valleys of energy demand. An advanced energy-management system (EMS) allows you to do this safely by strategically directing demand reductions through a collection of selected loads to achieve the desired kW reduction while maintaining productivity (Fig. 2). The savings can be significant. Peak-time energy use can account for as much as 40% of an industrial user’s electricity bill, and avoiding these spikes can reduce the overall bill by as much as 15%. Demand Response

This is a demand-reduction strategy being

implemented by utilities and power-system operators across the country. Demand response (DR) programs let you earn money by curtailing your electricity use on demand. For example, on an unusually hot summer day a utility might notify demand response participants that it needs them to curtail their usage by an amount specified in their participation contract. There are two types of DR programs. In standby/reliability programs, you commit to specific load reductions when the grid is under stress. These infrequent events often last two to four hours (Fig. 3). Prices are usually $30,000 to $60,000 per MW. In reserves/market-based programs, you agree to cut usage based on a set price. Events are more frequent than standby/ reliability events and usually last one hour or less. Prices are typically about $40,000 per MW. Some of the more lucrative DR programs require automated communication between the energy users’ and supplier’s DR systems. Dynamic Pricing Optimization

Many utilities employ dynamic pricing strategies, such as real-time pricing (RTP), that involve rate changes based on the market price of electricity, weather events or other conditions. These changes can happen with anywhere from just minutes’ to 24 hours’ notice, and in worst-case examples, power costs have jumped during an RTP spike to more than 100 times the normal rate. An advanced EMS lets you respond automatically to ongoing price fluctuations by shifting consumption to lower rate periods or reducing consumption during costly super-peak times.

Energy nergy y Efficiency

Energy rgy effi efficiency ciency – not only using less energy, but also using energyy at the least costly times – is often a byproduct of implementing demand control, demand response and dynamic pricing programs. These initiatives typically reveal bestpractice opportunities for eliminating waste and optimizing use. Only a small fraction of industrial businesses takes advantage of these prime saving opportunities, but the few that do demonstrate the potential. For example, the Blackhawk de Mexico foundry in Santa Catarina, Nuevo Leon, Mexico uses Powerit’s Spara technology to decrease its kilowatt-hour usage 10-12%, reduce peak period demand usage 37% and save $20,000 per month on its power bill. Why Automation is Essential Manually manipulating complex processes to achieve energy savings is difficult

Demand control

Demand response

Energy Management System

Energy efficient

Pricing response

Fig. 1. A diverse energy-management strategy will create more opportunities to save and be less risky than a single, aggressive measure. IndustrialHeating.com - June 2011 45

FEATURE | Heat Treating

Demand control setpoint

Demand spikes

kW

Shifted kW load

DR baseline

Curtailment event duration

2900

2600

2600

2300

2300

2000

2000

1700

DR curtailment commitment

kW 2900

1700

to impossible for most companies. It can also introduce human error and potentially compromise production. And the scope and types of loads that can be shed using manual approaches are limited, making participation in DR programs or response to dynamic pricing impossible or unprofitable. An advanced EMS is essential to getting full value from the spectrum of loadshedding strategies, and the investment is more manageable than many facility operators expect. Depending on incentives available in your area and your implemen-

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Fig. 2. Random, coincidental spikes in kW result in high peakdemand charges. An EMS can shift or delay kW use, lowering peaks while protecting site productivity.

10:00 am

DR setpoint

1400

8:00 am

1400

Fig. 3. Using an EMS to control demand response participation will increase kW participation and lower risk of under/over performance.

tation, it’s possible to achieve ROI anywhere from immediately to 18 months. Many utilities offer incentive programs that cover partial or even full costs of systems needed to reduce energy consumption or manage peak demand. These incentives cover a wide variety of equipment and technology for applications ranging from basic energy efficiency to automating participation in DR programs. Where incentive programs aren’t available, renting, renting to own and leasing often are attractive alternatives to outright purchases. These financing options

increase purchasing power and lower the upfront investment, allowing immediate action on reducing energy costs, even when there’s no budget for new technology. Depending on the circumstances, businesses may be able to realize tax benefits through bonus and accelerated depreciation or investment tax credits and can even realize immediate positive cash flow. An Advanced EMS at Work: A Real-World Example Here’s an example of a typical demand control operation at a metal-casting

Controlling Energy Use from Heat Treaters Vacuum heat-treating furnaces offer the best opportunity for demand control in heat-treating operations. The electrical load on this equipment is highest and most available for demand control during the ramp stage, when the load is heated from the ambient temperature to the soak temperature. With an advanced EMS controlling vacuum heat-treating furnaces, demand control might work like this: 1. The EMS is connected to the temperature-control system, handling the heating profiles of the furnace. Through this communication link, the EMS often knows the target and actual temperatures for both the furnace and the product and what stage (ramp or soak) the furnace is in. 2. The EMS constantly monitors the plant’s main electrical meter and calculates the demand reduction needed from heattreating furnaces to avoid breaching the peak demand setpoint. 3. The EMS polls the connected furnace controllers to identify which ones are operating and in ramp mode, making them available for curtailment.

46 June 2011 - IndustrialHeating.com

4. Furnaces in ramp mode receive a signal from the EMS with a command to reduce heating (and therefore kW). The EMS follows strict rules defined by the operator for how much power can be reduced and for how long. It also tightly controls the kW reduction to make only the minimum reduction needed to avoid the peak level. Furnaces can be prioritized based on treated parts, production schedules and so on. Once the EMS calculates that kW reduction is no longer needed, the furnace is released to resume heating according to its recipe. Note: Demand control should not be allowed or should be very tightly controlled during the critical soak phase, which requires a precise temperature for a prescribed time in order to ensure that you get the desired mechanical qualities. Other areas worth exploring for demand control include mass heating used for rolling operations and induction heat treating or annealing that takes place in a normal atmosphere.

©

BICOM_11052.02

0.04.2011

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FEATURE | Heat Treating

foundry that is controlling energy demand from furnaces using Powerit’s Spara EMS: 1. The EMS’s real-time algorithm predicts that the foundry’s current energy use will exceed its setpoint by 200 kW. The facility needs to shed loads. 2. The system determines which loads (furnaces, baghouse fans, etc.) are enabled for reduction at this moment. These loads are available for curtailment. 3. The EMS stages curtailment actions based on the preferred order that has been set in the system. Furnaces A and B have a priority of 1 and 2. Furnace A has 150 kW safely available for reduction, so the system powers it down accordingly. It then powers Furnace B down 50 kW to get the remaining reduction needed. 4. Each furnace can operate at reduced power for only so long without disrupting operations, and that time has been set in the system. The EMS monitors the reduction time and sees that Furnace A has hit that point. It releases Furnace A and further reduces Furnace B to get the rest of reduction needed. Note: Time as a constraint is a simple example of a rule that can be integrated into the system’s decisionmaking process. Rules can also be fairly complicated and logic based (if pump speed is X and tank level is Y then the agitator can be curtailed to speed Z) or triggered by schedules or production factors. 5. Now you’ve hit your goal. All loads are released according to the procedure set by the facility. What happened here? The foundry’s processes were interrupted, but they weren’t disrupted. The changes were defined in advance as acceptable power reductions in return for energy savings. What to Look for in Energy-Management Technology Key features of the best energy-management systems are: 48 June 2011 - IndustrialHeating.com

Fig. 4. An intelligent energy-management system verifies savings actions with a real-time connection to the utility meter.

• Ability to take direct control of the loads – within parameters you set – so that no human intervention is required. • Seamless integration with existing systems and the ability to extend their functionality. • Capacity to connect with many loads in order to take maximum advantage of potential savings. • Access to real-time data in order to analyze and predict events. • Rules-driven, process-protecting routines tailored to your operations that can manage an infinite variety of industrial processes, limitations and thresholds. • Wireless input/output, which eliminates the need to run costly conduit (often a disruptive and time-consuming process) and provides access to hard-to-reach places, ensuring that the maximum number of loads can be controlled. Beyond the technology itself, look for a vendor that can assist in identifying and evaluating utility programs, rebates and incentives. The vendor should also have expertise in your industry so that they’re

familiar with typical processes and equipment and can share best practices based on past projects. With the right technology partner, industrial users can significantly reduce previously uncontrollable energy costs. By being able to aggressively manage a monopoly-controlled resource that continues to rise in cost year over year, you can not only cut costs but also gain a competitive advantage (Fig. 4). In manufacturing, many companies can make a widget. It’s the company that makes the widget most efficiently that wins the market. IH For more information: Contact Bob Zak, president and general manager of Powerit Solutions North America, 568 First Ave South, Suite 450, Seattle, WA 98104; tel: 866499-3030; fax: 206-621-8545; e-mail: info@ poweritsolutions.com; web: www.powerit solutions.com

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FEATURE | Ceramics & Refractories/Insulation

It’s Easy Being Green Wendell Keith and Reto Fehr – Keith Company; Pico Rivera, Calif. Thirty years ago, Kermit the Frog from Sesame Street sang “It’s Not Easy Being Green.” Today, in our energy- and environmentally conscious society, being green is politically correct. It represents good environmental stewardship, and it is more profitable for your company to become green than you may realize! Kermit was actually ahead of his time, and today he could sing a different song titled “It’s Easy Being Green.”

T

h stand-alone performance he of o a well-adjusted modern furnace, at best, is only 30-40%. n However, other common inefH ficiencies can easily reduce this efficiency to just 15-20% because the furnace is operated with less than an ideal heating cycle, because it has old and deteriorated thermal insulation, and because its heating system is in disrepair. With such large inefficiency, there is plenty you can do to easily improve it by as much as 50%, which represents a huge financial opportunity for you and is the focus of this article. When figuring the payback of a repair or efficiency gain, it is perfectly acceptable if you calculate your efficiency gains based on the lifetime of the investment. Your own management typically wants to know what the payback is, so use this method of calculation. Contemporary management recognizes that best practices compel them to support energy-conservation initiatives within their company. I cannot think of a company that does not have a profit-making goal. Whether we call it profit making or energy savings, it is still the same idea. For some reason, the human spirit enjoys engaging in games they can win. Therefore, consider developing a couple of wellchosen goals and metrics that measure your progress toward those goals. You have probably heard the old adage, “if you can’t

measure it, you cannot control it.” Where Do You Look for Higher Energy Efficiency? If you don’t quite know where to find efficiency gains in your furnace area, here are some tips where to look for “low-hanging fruit.” In our 46 years of building and repairing industrial furnaces, we have seen plenty of examples of best and worst practices. Because the range of industrial heating applications varies widely among readers of this magazine, some of these tips may not apply to you, but please continue reading to discover tips that can help your business become more competitive and financially stronger, not to mention greener. Tip #1: Insulation Repair We choose to discuss this first because it applies universally to so many companies. This is one of the most common forms

Fig. 1. Bottom-loading furnace A with damaged and missing brickwork

Fig. 3. Front-loading furnace B with broken and missing insulation

of deferred repair work that we observe. Missing or damaged refractory allows excess heat leakage that the heating system must compensate for by overworking, thus raising your energy cost. Furthermore, heat leaks often mean cold-air infiltration into the furnace and upset temperature uniformity, thus lowering the yield of heat-treated product, which can also damage the equipment causing even more expensive repair. Pictured in Figures 1, 3 and 5 are classic examples of furnace interiors urgently in need of refractory repairs. Figures 2, 4 and 6 show furnace interiors with excellent refractory repair. The before and after story behind Figures 1 and 2 is that temperature uniformity became so bad in this furnace that there was no choice but to repair the brickwork. Otherwise, the furnace could not be used. This damage had been tol-

Fig. 2. Bottom-loading furnace A with heatseal brick replaced IndustrialHeating.com - June 2011 51

FEATURE | Ceramics & Refractories/Insulation

erated for several months, during which time it put the surrounding steel furnace structure at risk of being warped due to excessive heat losses. More importantly, it was ruining the temperature uniformity within the furnace, not to mention having to adjust its heating system to input greater heat to offset the cold air leaking into the furnace. The most expensive consequence of this damaged brickwork was the high energy inefficiency that was tolerated for several months before it was finally repaired. Tip #2: Conversion from Brick to Fiber Insulation If you operate a brick-lined batch furnace that heats to about 2100°F in 8 hours, soaks for 2 hours and then cools, you are a prime candidate for conversion to a fiberinsulated furnace. The justification for this is found in a comparison of the heat loss and heat storage between the two choices of refractory insulation constructions. For sake of example, assume your furnace has an interior volume of 6 x 6 x 6 feet. A furnace of this description insulated with 9 inches of brick will have double the heat storage per square foot of furnace lining compared with a fiber-insulated furnace. It is no surprise that the brick-lined furnace needs a heating system nearly twice as large compared to the fiber-insulated furnace. Which furnace would you rather pay the heating bill for? With the higher heat storage, a bricklined furnace will also effectively take twice as long to cool down, obstructing your ability to turn the furnace around every 24 hours. Using ceramic-fiber insulation can so substantially lower your energy bill, it is an alternative that warrants your serious consideration even before your brick-lined furnace insulation is on its “last leg.” Tip #3: Test and Adjust Your Burner System If your business uses a fuel-fired furnace, you probably know what type burner adjustment, control and furnace atmosphere (chemically) are most desirable for the particular material you heat (e.g., on-ratio, excess air or excess fuel). 52 June 2011 - IndustrialHeating.com

Fig. 4. Front-loading furnace B restored back to efficient heating condition

Fig. 6. Gas-fired, car-bottom furnace with newly installed ceramic-fiber wall and roof insulation

The manufacturer of your burners can most likely provide fuel-capacity curves stating heating capacities for various airflow rates for a particular fuel and operating temperature. Armed with this data and a digital monometer, you can set the correct gas and air settings on your burners accurately and easily. After setting the desired burner performance and furnaceatmosphere adjustments, it is possible to confirm them by measuring your flue-gas oxygen and carbon dioxide levels. Equipment needed to perform these burner and flue-gas measurements is not expensive, and if it is used periodically, you can be assured that your company is operating its furnaces in a fuel-efficient manner. The benefit of planning and achieving the correct gas/air ratio is quickly evident by understanding the graph (Fig. 7) showing available heat for differing rates of excess air assuming a 2000°F flue-gas temperature. Looking at Fig. 7, you can see that if you meant to be processing on-ratio (0% excess air) with 60°F combustion air but find from analysis of your flue gas that you are operating with 50% excess air, you

Fig. 5. A furnace needing repair of all insulation surrounding the door opening and of heating elements that were starting to fall loose

can determine from this chart that the fuel your furnace is burning is only utilizing 28% available heat rather than 46% (e.g., for 0% excess air). In effect, your furnace is consuming 65% more fuel than necessary. At today’s average national fuel cost of $3.50 MCF for a continuous process that consumes 1,000 ft3 of gas per hour, this amounts to burning $39,000 of annual profitability. One other important adjustment to your furnace’s combustion system concerns the operating pressure within your furnaces, which is controlled by the exhaust damper setting. Fuel-fired furnaces should be fired with a modestly positive pressure measured at hearth level (e.g., ÌiÜ>ÞÊ,`ÊÊUÊÊ ÀœœŽwi`]Ê7ÊxÎä{x

Phone: (909) 622-1091 Email: [email protected] • Website: www.mangoldengineering.com

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PARK THERMAL INTERNATIONAL (1996) CORPORATION New / Reconditioned Ovens Furnaces - Quenching Oils – Heat Treating Salts – Component Parts – Stainless Steel Foil – Refractory Products 62 Todd Road Georgetown ON L7G 4R7 Tel: (905) 877-5254 Toll Free: (877) 834-4328 (HEAT) Fax: (905) 877-6205 Email: [email protected] Web Site: www.parkthermal.com

THERMO TRANSFER INC. 1601 Miller Avenue Shelbyville, In 46176 317-398-3503 317-398-3548 fax E-Mail: [email protected]

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This is an excellent opportunity to join a growing company! In business for over 35 years, ThermoFusion, Inc serves diverse, strong industries. We are seeking energetic, driven individuals with thermal processing experience to become key additions to our team.

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Quality Technician • Strong written and verbal communication skills • Experienced with ISO 9001 Quality Systems • Familiar with AMS 2750 • Confident in tracking performance metrics • Proficient in Microsoft Office and Word

Lead Braze Technician • Experience in hydrogen brazing, torch brazing and vacuum furnace brazing. • Strong project management skills • Proficient in blue print reading • Some experience with quoting

ThermoFusion provides healthy and competitive compensation and an excellent benefits package including company-subsidized medical, dental, life insurance, LTD, 401(k) retirement program, and profit sharing program. Please send resumes to [email protected]

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Immediate Openings Available for: Plant Quality Assurance • Knowledge of heat treat, heat treat laboratory and pyrometry operations. Min of 5 years Quality System Management (ISO 9001:2008/AS 9100 or equivalent) • Nadcap process management • Heat treat process management • Internal audit experience (process and QMS auditing) • RCCA experience • Creating and implementing process control plans • Basic Statistical Process Control • General knowledge of Corner Stone software (Visual Shop) • Computer skills (word, excel, PowerPoint, Adobe) • Team builder and team attitude • College degree preferable

Experienced Maintenance Personnel • Qualified candidates shall be skilled in the following areas: • Vacuum furnaces / Mechanical pumps • Welding / Pipe Fitting • Combustion Systems • Reading mechanical and electrical blueprints • Motor Wiring and Troubleshooting • PLC operation and Ladder Logic Diagrams

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Industrial Heating REPRINT PLAQUES are Now Available Contact Becky McClelland at 412-306-4355 for Details 72 June 2011 – IndustrialHeating.com

LHS Air Heater

Built-in thermocouple with digital temperature readout

Upgrade your LE to a Next Generation LHS air heater today www.leisterusa.com Toll-free: (855) Leister [email protected]

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Brazing Furnace For Sale Seco Warwick 18"W x 9"H x 10'L x 30'L, 2150-F, 175 kW, Includes New Alloy Muffle

FOR SALE Park Thermal Electric Re-Circulating Furnace 120 KW, 52" W x 50" H x 9' long, 1400ÝF. Complete with Digital Controls. Mint Condition.

Park Thermal Mesh Belt Tempering Furnace Furnaces, Ovens & Baths, Inc. 4790 White Lake Road, Clarkston, MI. 48346 248.343.1421 – Phone 248.625.4030 - Fax Email: [email protected]

36"w x 22' long x 16" high, 120 kW, 1250ÝF, complete w/controls

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Hot Zone Rebuild & Upgrade Vacuum Furnaces Controlled Atmosphere Furnaces Hydrogen Retort Furnaces 525 Klug Circle Corona, CA 92880-5452 Phone: (951) 340-4646 Email: [email protected] or [email protected]

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18” wide x 9” high x 60” diameter 72 kW; 1500ÝF. Complete with control system

Lightnin Mixers (8) Available 5 HP, 1725 RPM, Complete w/ propellers and agitators. Shaft length 46" L, Small Propellers 8"W - Large Propellers 19"W For more information, please call your sales representative at 1-877-834-4328 (HEAT).

Park Thermal International (1996) Corp. 62 Todd Road, Georgetown, Ontario L7G 4R7 Toll Free: 877-834-4328 • Fax: 905-877-6205 [email protected] • Web: www.parkthermal.com

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(2) Ipsen P-6 Pusher Carburizers

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• Gas Fired Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750ÝF, with Top Cool, SBS chiller and controls. • Electric Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750ÝF, 140 KW with Top Cool, SBS cooler and controls. • Electric Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750ÝF, 180 KW with SBS cooler and controls. • Electric Tempering Furnace 30” x 48” x 30”, 1400ÝF, 81 KW with controls. • Electric Dunk Washer 30” x 48” x 30”, 180ÝF with controls.

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FOR $25.00 WE WILL POST AND LINK YOUR AD ONLINE Visit industrial heating online at www.industrialheating.com

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Park Thermal International (1996) Corp. 62 Todd Road, Georgetown, Ontario L7G 4R7 Toll Free: 877-834-4328 • Fax: 905-877-6205 [email protected] • Web: www.parkthermal.com

FOR SALE

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FOR SALE FOR OVER 45 YEARS, specializing in buying and selling used Heat Treating, Heat Processing and Metal Finishing Equipment worldwide.

   

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“Featured Equipment” • Surface Combustion 6000 Endo, Gas Air Cooled • Vac Aero 6 bar, 2400ÝF, 36"x 48"x 30" • Surface Combustion 36"x72"x36" Top Cool I/Q Line • Lindberg 24 " x 36 " x 18" Vacuum Furnace • Various pieces of Induction Equipment Enterprise Equipment Co., Inc. 6000 Caniff Ave.,Detroit, MI 48212 Ph: 313-366-6600 • Fax: 313-366-6603 Web: www.eecoinc.com Email: [email protected]

74 June 2011 – IndustrialHeating.com

• • • • • •

36”W x 30”H x 48”L, Surface Combustion, 1500˚F, Electric IQ H2O Quench 36”W x 30”H x 48”L, Ipsen, I/O Internal Quench, Gas, 1850˚F, 2 Units 24” Diameter x 48” Deep, L & N Pit Nitrider, 1750˚F 40”W x 18”H x 36’L, Holcroft Roller Hearth, Gas, 1300˚F Box Furnaces – All Sizes (30) In Stock Conveyor Ovens – All sizes (20) In Stock • 30” x 48” x 30”H, Lindberg Batch Tempers, 1250˚F, 3 Available • 72"W x 6"H x 24' , Holcroft, Atmosphere, 1600˚F, Mesh Belt • 102” x 72” x 16”H, Holcroft Slot Forge, 2200˚F, Gas, UNUSED • 21” x 42” Tray Size, Holcroft 2 Row Pusher, 1750˚F, Direct Fired, Cooling • Lean Fume Afterburner, Surface Combustion, 1800˚F, 2000 SCFM • Progressive Technologies Rotary Index Shot Peeners • Induction Heating, 7.5 kW to 750 kW, 1 kHz to 450 kHz, 21 In Stock • 36” x 48” x 30”H, Surface Combustion Batch Tempers, 1400˚F, Gas • 59”W x 67”H x 50”L, Despatch, 1000°F, Atmosphere w/Forced Cooling, 2 Available • 8 Cubic Feet Jet Wheel Blast Multi Tumble Shot Blast Machines w/Loader, 2 Available • Dual Rotary Drum Washer, 2 Stage w/Blow Off, 23” Diameter x 15’L, Stainless Drums • SBS Air to Oil Heat Exchangers – 2 Available

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EQUIPMENT FOR SALE

Mowry Enterprises, Inc. New

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Canefco Direct Gas Fired Draw Furnace 11' wide x 75' long (in heat) x 13" high. Max temp 900 ÝF, net capacity 15,000 lbs, 3 zones of control. Comes with re-circulating fans and free standing control panel. For more information, please call your sales representative at 1-877-834-4328 (HEAT).

Park Thermal International (1996) Corp.

For Sale

62 Todd Road, Georgetown, Ontario L7G 4R7 Toll Free: 877-834-4328 • Fax: 905-877-6205 [email protected] • Web: www.parkthermal.com

VFS 6 BAR, 36 x 36 x 48: graphite hot zone, high vacuum, internal quench, 2650 F, PLC/ touch screen controls Ipsen 224, 15” x 10” x 24” , 2002 control panel, rebuilt pump, graphite elements, mech pump/ diffusion pump

FOR SALE

VACUUM OIL QUENCH CARBURIZER: C.I. Hayes: 24” x 24” x 24”, Still installed, 2 chamber with isolated oil quench, complete with water recirc system and alloy grids. Heat Chamber is 24 24 36. Quench chamber can be modiÀed for this larger load. VFS HL 36: 2500 F, 24” x24” x38” graphite hot zone, High vacuum, PLC/ touch screen controls, Pressure Quench

Bring Your Heat Treating In-House

VFS HL 50: 36” x 30” x 48”, graphite hot zone, high vaucum, 1200 CFM external quench, 2650 F 2 BAR: 10” x 10” x 20” hot zone, Graphite. Mech pump and blower, built in 1999. TM 12 x 12 x 20: graphite hot zone, high vacuum, internal quench, 5 psig positive quench ABAR 48 x 48 bottom load: graphite hot zone, high vacuum, external quench, PLC/ touch screen controls

www.mowryenterprises.com email: [email protected] Phone: 978-808-8634 Fax: 508-845-4769

• • • • •

Energy Efficient Temperatures to 3000˚F Electric or Gas Atmospheres Easy to Operate

WWW.LUCIFERFURNACES.COM • Phone: (800) 378-0095 • Fax: 215-343-7388 IndustrialHeating.com – June 2011 75

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Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

IC M A R E . B LE C T PA M T E S T GH C A ALAN FOR SALE

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––––– ATMOSPHERE GENERATORS ––––– 750CFH Endothermic Ipsen (Air) Gas 1000CFH Ammonia Dissoc. Drever Elec 1000CFH Ammonia Dissoc. Hayes (1994) Elec 1000CFH Exothermic Gas Atmos. Gas 1500CFH Endothermic Ipsen Elec 3000CFH Endothermic Lindberg (3) Gas 3000CFH Ammonia Dissoc. Drever Elec 5600CFH Endothermic Surface (5) Gas 6000CFH Gas Atmos. Nitrogen Generator Gas 10.000CFH Exothermic Seco/Warwick (2) Gas –––––––––– BOX FURNACES –––––––––– Huppert Elec 2000˚F 8" × 12" × 6" 9" × 14" × 9" Lucifer Up/Down Elec 2000/1250˚F 9" × 18" × 9" Lucifer Up/Down Elec 2000/1250˚F 12" × 24" × 8" Lucifer Up/Down (Muffle) Elec 2100˚F 12" × 24" × 8" Hayes (Atm) Elec 1800˚F 13" × 24" × 12" Electra Up/Down Elec 2000˚F 12" × 24" × 8" Fce. Works (Muffle) Gas 2000˚F 14" × 24" × 12" Lindberg H2 Retort Elec 2150˚F 17"×14.5"×12" L&L (New) Elec 2350˚F 24"×36"×18" Lindberg Elec 2000˚F 24"×36"×24" Lindberg Elec 2100˚F 30" × 48" × 30" Surface (RTB-Atmos.) Gas 1750˚F 39" x 144" x 56" Nabertherm Kiln Elec 2450˚F 72" x 72" x 48" R&G Gas 2000˚F R&G Elec 2000˚F 72"×72"×48" –––––––––– PIT FURNACES –––––––––– 22" Dia × 26"D L&N Elec 1400˚F 22" Dia × 26" L&N Nitrider Elec 1200˚F 28" Dia x 48" Lindberg Elec 1400˚F 40" Dia × 60"D L&N (steam) (2) Elec 1200˚F 48" Dia × 72"D Surface Gas (R.T.) 1850˚F 60" Dia × 144"D Lindberg Elec 1400˚F ––––––––– VACUUM FURNACES ––––––––– Elec 2400˚F 24" × 36" × 18" Ipsen VFC-424 –––– INTEGRAL QUENCH FURNACES –––– 8" × 18" × 8" Ipsen Gas 1850˚F 15" × 24" × 10" L&N Tricarb Elec 1850˚F 24" × 36" × 24" Lindberg (Top Cool) Elec 2000˚F 24" × 36" × 24" Surface Gas 1750˚F 30" × 30" × 30" Ipsen P-6 Pusher Gas 1850˚F 30" × 48" × 30" Surface Elec 1750˚F 30" × 48" × 30" Surface Gas 1850˚F ––––––– BELT FURNACES/OVENS ––––––– 24" × 5' × 6" Darvon (New) Elec 400˚F 12" × 15' × 4" Sgt. & Wilbur (1994) Muffle Gas 2100˚F 16" × 24' × 4" Abbott (Atmos.) Muffle Elec 2400˚F 24" × 17' × 28" Jensen – Dual Belt Gas 500˚F 24" × 19' × 30" Jensen Gas 500˚F Gas 500˚F 24" × 30' × 30" Jensen 24" × 40' × 18" Despatch Elec 500˚F 24" × 40' × 18" Despatch Gas 650F 28" × 18' × 12" Hayes Elec 800F 32" × 21' × 18" Sunbeam Elec 1450˚F 36" × 108" × 34" Process Heating Elec 300˚F 42"× 24'× 30" Jensen Gas 500˚F 60"×45'×12" W-House Roller Hearth Gas 1700˚F

76 June 2011 – IndustrialHeating.com

–––––––––– MISCELLANEOUS –––––––––– 30” × 48” Lindberg Charge Car (double-ended) 4000# Accurate — Skip Hoist (NEW) 30"× 48"× 30" Dow Washer (D&S) Elec New Carbon Probes 36" × 48" Surface Roller Tables 30" × 48" Surface Charge Car (System I) 30" × 120" × 12" Ransohoff Belt Washer/Dryer Gas 60" Diam Surface Rotary Hearth (RT) Gas Wilson Hardness Testers (RC) SBS Air/Oil Coolers ––––––– OVENS/BOX TEMPERING –––––– 12" × 18" × 12" Surface Gas 1250˚F Elec 1250˚F 12" × 18" × 12" Lucifer 12" × 16" × 18" Lindberg (3) Elec 1250˚F 14" × 14" × 14" Blue-M Elec 1300˚F 14" × 14" × 14" Gruenberg (solvent) Elec 450˚F 15" × 24" × 12" Sunbeam (N2) Elec 1200˚F 15" × 24" × 18" Lindberg Elec 1250˚F Gas 1200˚F 18" × 36" × 18" Surface 18" × 48" × 18" Lucifer Elec 1400˚F 20" × 18" × 20" Blue-M Elec 400˚F Elec 650˚F 20" × 18" × 20" Blue-M 20" × 18" × 20" Blue-M (3) Elec 800˚F 20" × 20" × 20" Gruenberg (Solvent) Elec 450˚F 20" × 18" × 20" Despatch Elec 500˚F 20" × 24" × 20" Despatch Elec 1350˚F Gas 500˚F 24" × 26" × 24" Grieve 24" × 24" × 36" New England Elec 800˚F 24" × 24" × 48" Blue-M (2) Elec 600˚F Elec 500˚F 24" × 36" × 24" Demtee (N2) 24" × 36" × 24" Paulo Gas 1250˚F 25" × 20" × 20" Blue-M Elec 650˚F Elec 1300˚F 25" × 20" × 20" Blue-M 26" × 26" × 38" Grieve (2) Elec 850˚F 30" × 48" × 54" Lindberg Gas 1250˚F Elec 400˚F 36" × 24" × 24" Young & Bertke 36" × 24" × 48" Blue-M Elec 600˚F 36" × 36" × 36" Grieve (2) Elec 650˚F Elec 500˚F 36" × 36" × 36" Grieve 36" × 36" × 36" Trent Elec 1200˚F 36" × 36" × 48" Blue-M Elec 600˚F Elec 850˚F 37" × 19" × 25" Despatch 37" × 25" × 50" Despatch (3) Elec 500˚F Elec 650˚F 36" × 60" × 36" CEC (2) 36" × 36" × 60" Hevi-Duty Elec 850˚F 36" × 36" × 120" Steelman Elec 450˚F Elec 850˚F 38" × 20" × 26" Grieve 38" × 26" × 38" Grieve Elec 1250˚F 38" × 28" × 28" Trent (Top load) Elec 900˚F Elec 600˚F 48" × 24" × 48" Blue-M 48" × 30" × 42" Despatch Gas 850˚F 48" × 30" × 48" P-Quincy Elec 500˚F Elec 450˚F 48" × 48" × 72" Lydon Bros. 48" × 48" × 84" Gruenberg Elec 450˚F Elec 500˚F 48" × 72" × 72" Mich. Oven 50" × 50" × 50" Grieve Gas 850˚F 54" × 30" × 60" P-Quincy Elec 350˚F 60" × 64" × 72" Poll. Cont. Burn-off Gas 850˚F Gas 850˚F 66" × 192" × 84" Lanly 72" × 48" × 89" Grieve (S.S.) Elec 500˚F Gas 750˚F 72" × 96" × 72" Despatch (2) 72" × 72" × 72" Mich. Oven Gas 500˚F 72" × 120" × 72" Grieve Gas 450˚F Gas 1000˚F 72" × 144" × 42" Bowman (Car) Gas 750˚F 84" × 96" × 72" Despatch (2) 96" × 120" × 96" Poll. Cont. Burn-off Gas 850˚F

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Industrial Heating

REPRINT PLAQUES ARE NOW AVAILABLE An excellent marketing opportunity

Contact Becky McClelland at 412-306-4355 for details

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Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

FOR SALE

FOR SALE

VACUUM PUMPS

FOR SALE

SALES AND SERVICE

CASHVAC INC. • • • • •

25 years experience Guaranteed rebuilding Warrantied service OEM replacement parts New and used pump sales All makes and models

• FREE ESTIMATES AND DELIVERY

Surface Combustion Gas Fired Integral Quench Furnaces. (4 Available) With washers, tempers and generators. Working dimensions: 30" w x 30" h x 48" d; Rated: 2500 lbs./hour; c/w controls

Factory Trained Stokes Pumps/Blowers

TOLL FREE: 1-800-397-1600 Specializing in Stokes Vacuum Pumps

Park Thermal Gas Fired Mesh Belt Furnace 1250ÝF, 65" w x 27' long x 4" high, natural gas, complete with free standing control panel. For more information, please call your sales representative at 1-877-834-4328 (HEAT).

FOR SALE

Park Thermal International (1996) Corp. 62 Todd Road, Georgetown, Ontario L7G 4R7 Toll Free: 877-834-4328 • Fax: 905-877-6205 [email protected] • Web: www.parkthermal.com

Fax Your Ad To: Becky McClelland at 248-502-1076 Or Mail To: Industrial Heating Manor Oak One, 1910 Cochran Road, Suite 450, Pittsburgh, PA 15220 Or Call (412) 306-4355 • Email: [email protected]

ASM – 1933

Hold on to your Hats! We’re headed to Cincy! Discover the art and science of heat treating. Register today.

October 31-November 2, 2011 Duke Energy Convention Center • Cincinnati, Ohio USA

Gear Up for Success and join innovators, influencers and decision makers in the heat treating industry from around the world for the 26th ASM Heat Treating Society Conference and Exposition – Heat Treat 2011. Be sure to plan to attend and support this global event. Visit www.asminternational.org/heattreat for the latest conference and exposition information. Sponsored by:

Media Sponsor:

IndustrialHeating.com – June 2011 77

Advertiser Website Index Page

Company

Phone

Website

36

AEC Inc.

847-273-7703

www.aecinternet.com

5

AFFRI, Inc.

224-374-0931

www.affri.com

27

Agilent Technologies, Vacuum Products Div.

800-882-7428

www.agilent.com/go/varian

25

Americarb

419-281-5800

www.americarb.com

49

ASCO--Emerson Industrial Automation

800-972-2726

www.ascovalve.com/ModularValves

77

ASM International

800-336-5152

www.asminternational.org

40

Can-Eng Furnaces Ltd.

905-356-1327

www.can-eng.com

31,44

CEIA USA Ltd.

888-532-CEIA

www.ceia-usa.com

62

Centorr Vacuum Industries, Inc.

800-962-8631

www.centorr.com

43

Ceramic Solutions Inc.

936-588-2646

www.ceramicsolutionsconroe.com

39

DMP CryoSystems

915-351-8500

www.CryoSystems.com

15

Dry Coolers Inc.

800-525-8173

www.drycoolers.com

50

Eclipse, Inc.

800-800-3248

www.eclipsenet.com

19

G-M Enterprises

951-340-4646

www.gmenterprises.com

60

Graphite Metallizing Corp.

914-968-8400

www.graphalloy.com/IH

34

H.C. Starck Inc.

617-584-9322

www.hcstarck.com

30

Hauck Manufacturing

717-272-3051

www.hauckburner.com

65

Herring Group, The

630-834-3017

59

IH Training

36

Induction Tooling Inc.

440-237-0711

www.inductiontooling.com

21,53

Inductotherm Group

609-267-9000

www.inductothermgroup.com

62

INEX Incorporated

716-537-2270

www.INEXinc.net

3,56

Ipsen, Inc.

800-727-7625

www.ipsenusa.com

6

Keith Company

800-545-4567

www.keithcompany.com

33

Mersen

01 46 91 54 00

www.mersen.com

29

Nanmac Corp.

508-872-4811

www.nanmac.com

Inside Back Cover

Nutec Bickley

52-81-8151-0800

www.nutecbickley.com

47

Oerlikon Leybold Vacuum USA

724-327-5700

www.oerlikon.com/leyboldvacuum

13

Pyromaitre Inc.

418-831-2576

www.pyromaitre.com

Back Cover

SECO/WARWICK Corp.

440-327-5000

www.secowarwick.com

37

Sevenstar

010-64348388

www.sevenstar.com.cn

23

SGL Carbon, LLC

800-727-4474

www.sglcarbon.com

4

Solar Manufacturing

215-258-3350

www.solarmfg.com

37

Southern California Gas

800-847-5497

www,socalgas.com/incentives

7, 55

Steeltech Ltd.

616-243-7920

www.steeltechltd.com

Inside Front Cover, 38

Struers, Inc.

888-787-8377

www.struers.com

8

Surface Combustion Inc.

800-537-8980

www.surfacecombustion.com

11

Unifrax LLC

716-278-3800

www.unifrax.com

17

WIRCO, Inc.

800-348-2880

www.wirco.com

35

Wisconsin Oven Corp.

262-642-3938

www.wisoven.com

65

WS Thermal Process Technology Inc.

440-365-8029

www.flox.com

39

Yeten Combustion and Energy Technologies

90 216 420 22 18

www.yeten.com

78 June 2011 - IndustrialHeating.com

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