Zink Körner cuts energy consumption in galvanizing by 15 percent
Efficient furnaces for hot dip galvanizing
The new RECU-CHANNEL recuperative heat exchanger system may achieve energy savings of more than 15 percent in batch-parts, wire and small-parts galvanizing. In typical batch-parts galvanizing plants, this may result in approx. 30,000 euros saved on natural gas costs every year.
For galvanizing at temperatures between 450 and 460 °C, Zink Körner has developed its new RECU-TEC hot dip galvanizing technology, which allows the input energy to be recovered directly in the furnace. These furnaces are equipped with a steel tank and natural-gas fired flat flame burners.
Innovative recuperation technology
The new RECU-CHANNEL recuperative heat exchanger system heats the kettle very uniformly and exactly to the required temperatures. Operation of the furnace requires more than 15 percent less energy than traditional systems. Thus, more than 30,000 euros per year can be saved on natural gas costs, for example, in case of a batch galvanizing plant with an average through-put rate of 6 tons per hour.
While in conventional systems without RECU-CHANNEL technology the waste gas collects at the top, RECU-CHANNEL systems suck the waste gas from below in a controlled way allowing the waste gas to flow downwards past the outside surface of the kettle wall. Thus the waste gas transfers to the lower part of the tank exactly that amount of energy that is required for the process.
The channels are arranged at both long sides of the furnace extending along their complete length. Thus the waste gas travels long distances, giving it more time for the heat transfer. Using the residual heat in the RECU-CHANNEL to preheat the combustion air leads to a further increase in furnace efficiency.
The result: While the waste gas temperature of furnaces without RECU-TEC usually reaches 550 °C or more, the waste gas temperatures of the new furnaces are always below 400 °C, even in case of full load operation. This is a clear indication that the input energy is extremely efficiently used.
Highly efficient burner technology
Zink Körner has developed the modulated KÖRNER FL 15/80 flat flame burners specifically for the heating of steel kettles. These burners feed just as much energy to the galvanizing furnace as necessary at any point in time.
Unlike intermittent burners, they operate with a combustion air ratio of only 1.10 – hence with much less surplus air than usual. Their efficiency is 10 to 20 percent higher and gas consumption correspondingly lower than that achievable by burners operating with a ratio of, let“s say, 1.20.
Additionally, the modulating operation avoids short-term consumption peaks. This saves on gas procurement costs as the gas suppliers calculate their provision fees based on the peak load of the furnace.
Each of the diffuser plates of the new burners is supported by three rods fix mounted to the burner port. This arrangement achieves constant pressure conditions which allow the flame to be adjusted with utmost precision. For the user this provides the benefits of ideal combustion ratios and minimal gas consumption.
The burners are installed along the long sides of the furnace at two thirds of the furnace height (from the bottom). At that position, the heat requirement is highest due to the heat loss at the bath level.
About Zink Körner
Zink Körner GmbH designs and manufactures the complete array of hot-dip galvanizing equipment for single parts, tubes and pipes, miscellaneous small parts and centrifugal parts.
The supply range encompasses complete galvanizing plants, including pretreatment and handling equipment. The company provides design, engineering, manufacture, installation, commissioning and after-sales services. Zink Körner maintains a worldwide network of branches and licensees.
Zink Körner has launched many pioneering developments during its company history. For example, as early as at the beginning of the 1970s the company built the first automated centrifugal galvanizing plants, which have markedly improved the quality of the end products and the energy efficiency of the galvanizing process. The company took another innovative move by developing dedicated burner technology for hot-dip galvanizing applications.
Zink Körner is a company of the Körner Group, which was established in 1928. Thus the Group builds on more than 80 years of experience in industrial furnace technology and auxiliary equipment.
Within the Group, Wire Körner GmbH designs heat treatment equipment for wire and narrow strip. TVT Kordt GmbH develops plants for thermal process technology, with a focus on industrial furnaces for the heat treatment of steels, special steels and non-ferrous metals.
Firmenkontakt
Zink Körner GmbH
Peter Kordt
Profilstrasse 9
58093 Hagen / Germany
0049.2331.800 6-0
0049.2331.800 6-10
info@koerner-hagen.com
http://www.koerner-hagen.com
Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de
