Design with emphasis on resource saving
Zink Körner has successfully implemented the order for Wiegel Neuwied Feuerverzinken GmbH & Co KG, covering the supply of a batch-galvanizing furnace for the new Neuwied facilities. By introducing design features such as infinitely adjustable, modulating flat flame burners, a wall construction with a markedly reduced heat transfer and a novel reflecting refractory coating, Zink Körner has significantly increased the energy efficiency of batch galvanizing. The new furnace has been in „liquid“ operation since May 5, 2013. In early June, Wiegel commissioned the complete galvanizing line in its new works in Neuwied.
In response to the growing demand for hot-dip galvanized components, Wiegel has built a new hot-dip galvanizing plant in Neuwied – the most modern and environmentally friendly of all plants operated by the Wiegel Group. The galvanizing furnace was supplied by Zink Körner. The new furnace is mainly used to galvanize structural components made of steel or other metals.
The galvanizing tank is 15.5 m long, 3.2 m deep and 1.8 m wide. These dimensions enable it to handle parts of up to 15.3 m length. The plant is designed for throughput rates of up to 16.5 t/h.
Smooth and mild heating
The furnace features 14 flat flame burners of the FL 20/50 type, which Körner developed specifically for batch galvanizing. These burners use natural gas as fuel, which is available at relatively moderate cost. Their design allows them to provide the same smooth and mild heating as previously only achievable by electrically heated furnaces.
The burners achieve an efficiency of >72 percent. This makes Zink Körner a market leader also in terms of energy efficiency. Unlike burners commonly used in the past, they operate in a modulating mode which makes them infinitely adjustable within a range of 1:10.
Diffusor plates mounted on the burners direct the gas flow along the inner furnace wall. This produces a combination of radiant and convective heat, which has the positive effect that a high input of heat into the liquid zinc is achieved at relatively low furnace temperatures.
Peter Kordt, Managing Partner of Zink Körner, explains why the furnaces operate at such an excellent efficiency level: „We exploit every possibility that may help reduce the consumption of energy. Let“s take, for example, the flat flame burners, which we developed specifically for use in batch galvanizing. Compared with plants using non-continuous burners, furnaces using our flat flame burners achieve impressive energy savings of, for example, some 500,000 kWh in a facility with a throughput rate between 10 and 15 t/h operated in two shifts for 4,000 hours per year. At a price of 5 cents per kWh, this results in cost savings of 25,000 euros per year.“
The output of the burners is constantly infinitely adjusted to the throughput of the furnace. Thus the temperature drop in the zinc bath caused by the dipping of a new batch is minimized. Another positive feature is that the furnace always consumes just the amount of energy needed in a certain situation. This regulating mode also avoids abrupt temperature changes, which otherwise would cause strain in the galvanizing tank structure. Thanks to these features, furnaces from Körner achieve long service lives.
Controlling the overpressure in the furnace chamber guarantees that the heat is evenly distributed in all areas of the furnace and that the energy is optimally exploited.
High energy efficiency
The multi-layer, 300-mm-thick insulation material reduces heat losses. As an additional measure, the internal surfaces of the furnace are covered with a reflecting refractory coating. This coating protects the furnace insulation against erosion and cuts thermal losses. This results in lower furnace wall temperatures, a lower waste-gas temperature and, consequently, higher efficiency.
As the waste-gas ducts are installed inside the furnace, they also contribute to a uniform, extensive and smooth heating of the tank. Körner also uses the waste heat from the furnace to heat the inlet air.
The entire firing system achieves efficiencies better than 72 percent. In hot-dip galvanizing applications, such high efficiencies used to be achieved only by electric heating systems, which are much more expensive.
Dr.-Ing.Thomas Happle, Managing Director Technology of the Wiegel group, explains his decision: „Our company is renowned for its awareness of resource utilization, which we have repeatedly demonstrated in numerous projects. With its highly efficient burners, elaborate control system, consistent insulation concept and its heat recovery system, the new furnace for the Neuwied plant represents the optimum of what is currently available on the market.“
About Wiegel
With almost 30 plants in Germany, Austria, Slovakia and the Czech Republic, the Wiegel Group ranks among the leading operators of hot-dip galvanizing plants in Europe. Founded in 1948 in Franconia, a region in southern Germany, the family-owned company has systematically undertaken continuous efforts and implemented solutions which have resulted in savings on energy and other valuable resources, and in the reduction of CO2.
With closed material circuits and most modern filter technology, Wiegel minimizes the impact on the environment and optimizes the use of energy during production.
About Zink Körner
Zink Körner GmbH designs and manufactures equipment for the hot-dip galvanizing of steel 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.
Kontakt
Zink Körner GmbH
Peter Kordt
Profilstrasse 9
58093 Hagen / Germany
0049.2331.800 6-0
info@koerner-hagen.com
http://www.koerner-hagen.com
Pressekontakt:
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstrasse 83
52072 Aachen /Germany
0049.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de
