FURNACES FOR FOUNDRY · 2021. 7. 26. · Tilting furnace K 150/12 Tilting furnace K 150/12 and...

www.nabertherm.com

FURNACES FOR FOUNDRY

1

MadeinGermany

Facts

Setting Standards in Quality and Reliability Experience in Thermal Processing

Global Sales and Service Network

· ProductionofArts&Crafts,laboratory,dentalandindustrialfurnacessince1947

· ProductionsiteinLilienthal/Bremen-MadeinGermany· 500employeesworldwide· 150,000customersinmorethan100countries· Verywideproductrangeoffurnaces· OneofthebiggestR&Ddepartmentsinthefurnaceindustry· Highverticalintegration

· Projectplanningandconstructionoftailormadethermalprocessplantsincl.materialhandlingandchargingsystems

· Innovativecontrolsandautomationtechnology,adaptedtocustomerneeds

· Veryreliableanddurablefurnacesystems· Customertestcenterforprocessassurance

· ThermalProcessTechnology· AdditiveManufacturing· AdvancedMaterials· FiberOptics/Glass· Foundry· Laboratory· Dental· Arts&Crafts

· ManufacturingonlyinGermany· Decentralizedsalesandserviceclosetothecustomer· Ownsalesorganizationandlongtermsalespartnersinallimportant

worldmarkets· Individualon-sitecustomerserviceandconsultation· Fastremotemaintenanceoptionsforcomplexfurnaces· Referencecustomerswithsimilarfurnacesorsystemsclosetoyou· Securedsparepartssupply,manysparepartsavailablefromstock· Furtherinformarionseepage54

Table of Contents

Processes

Whichfurnaceforwhichprocess?..................................................4Availableheatingconceptsandexhaustgassystems........................6

Tilting Furnaces

TiltingfurnacesK....................................................................... 10TiltingfurnacesKB..................................................................... 12TiltingfurnacesKBRwithrecuperativeburner................................ 14Productvideosmeltingfurnaces.................................................. 15TiltingfurnaceKC...................................................................... 16

Bale-Out Furnaces

Bale-outfurnacesT...................................................................20Transportablebale-outfurnacesTM.............................................22Bale-outfurnacesTB.................................................................24Bale-outfurnacesTBRwithrecuperativeburner.............................25Bale-outfurnacesTC.................................................................26

Furnaces for Special Applications

BathfurnacesB........................................................................30LaboratorytiltingfurnacesK/KC.................................................. 31Meltingfurnacesincustomizeddimensions...................................32CleaningfurnacesforrisertubesSRO..........................................35

Temperingplantsforaluminumandsteel.......................................46Furnacesforcontinuousprocesses..............................................48Waxburnout.............................................................................50Additivemanufacturing...............................................................52Energyefficiencyconcepts.........................................................53

Heat Treatment before and after Casting

Accessories and Process Control and DocumentationAccessoriesforbale-outandtiltingfurnaces.................................38Controlanddocumentationalternativesformeltingfurnaces............40Standardcontrollers,HiProSystemscontrolanddocumentation.......40Datastoringandvisualization......................................................42Functionsofthestandardcontroller.............................................43

3

Which Furnace for which Process?

Electricallyheatedtiltingfurnacesto1300°C

page10

Electricallyheatedbale-outfurnacespage20

Electricallyheatedlaboratorytiltingfurnaces

page31

Gas-firedtiltingfurnaceswithrecuperativeburner

page14

Gas-firedbale-outfurnaceswithrecuperativeburner

page24

Electricallyheatedtiltingfurnacesto1300°C

page10

Gas-firedbale-outfurnaces

page22

Tiltingfurnaceswithelectrohydrauliclifting

platforms,page32

Gas-firedtiltingfurnaceswithrecuperativeburner

page14

Tiltingfurnaces(SiC-rod-heated)to1450°C

page16

Gas-firedtiltingfurnaces

page12

Melt

Melting

Transportableelectricallyheatedbale-outfurnaces

page25

Electricallyheatedbale-outfurnaces

page20

Melting andHolding

Holding,Transporting

Meltingfurnacesforheavymetalsormagnesium

page33

Rotarytablesystemforcontinuouspouring

page32

Electricallyheatedbathfurnaces

page30

Bale-outfurnaces(SiC-rod-heated)to1450°C

page26

Transportablebale-outfurnaceTM150/10

Meltingfurnacesforheavymetalsormagnesium

page33

4

Chamberfurnacesforheatcleaning

seecatalogsbelow

Rotaryhearthfurnaces

page48

Forcedconvectionchamberfurnaces

seecatalogsbelow

Forcedconvectionbogie-hearthfurnaces

seecatalogsbelow

Chamberovens

page52

Electricallyheatedbogiehearthfurnaces

seecatalogsbelow

Forcedconvectionbogiehearthfurnaces

seecatalogsbelow

Temperingplants

page46

Drop-bottomfurnaces

page46


seecatalogsbelow

Gas-firedbogiehearthfurnaces

seecatalogsbelow

Heat Treatment of Forms and Cast Pieces

Dewaxing, Thermal Decoring/Cleaning

Pre-Heating, Drying

Additive Manufacturing

Chamberovens,includingsafetytechnologyaccordingto

EN1539(NFPA86)seecatalogsbelow

High-temperaturefurnacesfordebindingandsintering

page52

Continuousfurnaces

page48

Retortfurnaces

page52

Continuousfurnaces

page48

Electricallyheatedcleaningfurnacesforrisertubes

page33

Dewaxingfurnaces

page50

Artificial Ageing, Tempering,

Quenching, Annealing and Hardening

Chamberfurnaceswithgas-supplyboxes

page52

Fordetailedproductdescription,seecatalogAdditiveManufacturing:

Fordetailedproductdescription,seecatalogs

ThermalProcessTechnologyIandII:

Fordetailedproductdescription,seecatalog

ThermalProcessTechnology:

Fordetailedproductdescription,seecatalog

AdvancedMaterials:

5

Available Heating Concepts and Exhaust Gas Systems for Melting Furnaces

Alternative Exhaust Gas Systems

Extractionhood

Exhaustgases

Crucible

Burner

Alternative Heating Technologies

Theapplicationofalternativeheatingtechnologiesdependsontherequirementsformeltquality,productivityandenergyefficiency.Inprincipleeitherelectricallyorgas-firedmeltingfurnacescanbeused.Inthiscontext,withrespecttocoststhelocalpricingforthealternativeenergyplayadecisiverole.

Gas-Fired

Gas-firedmeltingfurnacesareidealformelting,particularlyifequippedwithexhaustgasdischargeoverthecrucibleedge.Sideexhaustgasdischargeisbestifahighmeltqualityisrequired.However,ahighermeltqualitymeansalowerenergyefficiencysinceafuel-firedfurnacewithsideexhaustgasdischargeconsumesapprox.20-25%moreenergythanameltingfurnacewithanexhaustgasdischargeoverthecrucibleedge.

Fuel-firedfurnacesprovideforoptimalenergyefficiencyincombinationwithhighestmeltqualityduetotheirburnersystemthatincludesheatrecoveryviarecuperator.Thehotexhaustgasesfromthemeltingfurnacepreheatthecombustionairfortheburnerviaaheatexchanger.Thissystemleadstosavingsofupto25%comparedtoconventionalfuel-firedfurnaceswithasideexhaustgasdischarge.

Electric Heating

Ifthemeltqualityandenergyefficiencytakepriority,anelectricallyheatedfurnaceisthebestchoice.Theheatingiscontrolledverysteadilyandprecisely.Themeltisnotpollutedthroughimmissionsfromafuel-firedheating.Electricallyheatedfurnacescanachieveupto85%ofthemeltingperformanceoffuel-firedfurnaceswithasideexhaustgasdischarge.Ifthefurnacesareusedonlyforholding,werecommendtheT…/10models,whichareveryenergyefficientduetotheirverygoodinsulationandreducedconnectedload.Fordemandingcopperalloysuptoameltingtemperatureof1320°C,theTC/KCmodelswithheatingviaSiCrodsarerecommended.

Exhaust Gas Discharge over the Crucible Edge

Exhaustgasdischargeoverthecrucibleedgeisthestandarddesignforourgasandoil-firedcruiciblefurn-aces,exceptfortheTBmodelsforfurnacetemperaturesof1200°C,sincethesefurnacesarenormallyusedasholdingfurnaces.Duetothehighmeltingperformance,thefurnacesareperfectlysuitedformelting.Thistypeofexhaustgasdischargeischaracterisedasfollows:

+ Veryhighmeltingperformance,idealforuseasameltingfurnace+ Lowpowerconsumptionsincethecrucibleisnotjustheatedfromtheoutsidebutpartoftheheatalso

entersthecruciblefromabove.Energysavingsofupto20%comparedtofurnaceswithasideexhaustgasdischarge

- Limitationsonthemeltqualityduetohigherburn-offandincreasedhydrogenabsorptionbythemeltfromtheexhaustgases

- Bathcontrolnotrecommended

Exhaustgasdischargeoverthecrucibleedge

6

Use Melting Material

Max. Melt Temperature

Productivity Melt Quality Energy Consumption

Noise Emissions

Models TB/KB (not for Models TB ../12)Exhaustgasdischargeoverthecrucibleedge Melting Al+Cu ++ ++ - o -

Models TB/KB Sideexhaustgasdischarge

Melting+Holding Al+Zn o + + - -

Models TBR/KBR Sideexhaustgasdischargewithrecuperator

Melting+Holding Al o + + + -

Models T/KElectricallyheatedwithbathcontrol

Melting+Holding Al+Zn o o +++ ++ +

Models T/KElectricallyheatedwithoutbathcontrol

Melting+Holding Al+Zn+Cu + o ++ ++ +

Modelle T/TM../10 Electricallyheatedwithbathcontrol Holding Al − - +++ +++ +

Models TC/KC ElectricallyheatedviaSiCrods

Melting+Holding Cu +++ + ++ + +

Decision Aid for Melting Furnaces

Toflue

Exhaustgas

Crucible

Burner

Side Exhaust Gas Discharge

b) with Recuperator TechnologyFuel-firedfurnaceswithburnersystemsthatincludeheatrecoveryviaarecuperatorprovideforoptimumenergyefficiencyinconnectionwithatopmeltquality.Thecombustionairfortheburnerispre-heatedwiththehotexhaustgasesfromthefurnaceviaheatexchanger.Thesystemresultsinsavingsofupto25%comparedtoconventionalfuel-firedfurnaceswithsideexhaustgasdischarge.

Dependingontheutilisationtherelativelyhigheracquisitioncostspayoffalreadyafterashortperiodoftime.

+ Burnersystemswitharecuperatorsystemsavearound25%ofthepowercomparedtofurnaceswithasideexhaustgasdischarge

+ Highmeltqualityduetolowburn-offandreducedhydrogenabsorptioninthemelt+ Reducedpowerconsumptionbyupto50%duringholdingwithaclosedswinglid+ Operatorexposedtolessheatintheareaabovethecrucible+ Bestmeltqualityifabathcontrolforaprecisetemperaturecontrolisused

- Lowermeltingperformancethanfurnaceswithexhaustgasdischargeoverthecrucibleedge- Powerconsumptionduringmeltingaround20-25%higherthanfurnaceswithexhaustgasdischargeover

thecrucibleedge

a) without Recuperator Technology Thesideexhaustgasdischargeisavailableforallfuel-firedcruciblefurnaces.Althoughthemeltingperformanceisnotashighaswithanexhaustgasdischargeoverthecrucibleedge,itprovidesforbettermeltqualityand,incombinationwithabathcontrol,ishighlyrecommendedforholdingoperation.

+ Highmeltqualityduetolowburn-offandreducedhydrogeninclusionsinthemelt+ Swinglid-reductionofpowerconsumptionupto50%duringholdingwithaclosedswinglid+ Operatorexposedtolessheatintheareaabovethecrucible+ Bestmeltqualityifabathcontrolforprecisetemperaturecontrolisused

- Lowermeltingperformancecomparedtofurnaceswithexhaustgasdischargeoverthecrucibleedge- Powerconsumptionduringmeltingaround25%highercomparedtofurnaceswithexhaustgasdischarge

overthecrucibleedge

Sideexhaustgasdischargewithrecuperatortechnology

Sideexhaustgasdischarge

7

Tilting Furnaces

Tiltingfurnacesarecharacterizedbyverygoodmeltqualityandhighmeltingperformancewithoptimumenergyefficiency.Dependingonthemodel,foraluminum,zincorcopperalloys.

Incl.crucible

Electro-hydraulictiltingdevicewithsafetwo-handoperationonthefurnace

ExclusiveuseofinsulationmaterialswithoutcategorizationaccordingtoECRegulationNo1272/2008(CLP)

Uniformandprecisepouringduetooptimumpivotpoint

Definedapplicationwithintheconstraintsoftheoperatinginstructions

Asadditionalequipment:ProcesscontrolanddocumentationviaNaberthermControlCenter(NCC)formonitoring,documentationandcontrol

8

Furnace Group Model Page

TiltingfurnacesK K 10

TiltingfurnacesKB KB 12

TiltingfurnacesKBRwithrecuperativeburner KBR 14

Productvideosmeltingfurnaces 15

TiltingfurnacesKC KC 16

9

Tilting Furnaces K ElectricallyHeated,forMeltingandHolding

Theelectricallyheatedtiltingfurnacesarecharacterizedbyverygoodmeltqualityandhighmeltingperformancewithoptimumenergyefficiency.Theyareidealasaflexiblesolutionforpre-meltingbutalsofordirectpouringintolargemoulds.

TiltingfurnaceK150/12

TiltingfurnaceK150/12andbale-outfurnaceT180/11aspremeltingandholdingsystem

Standard Equipment

· K../12foraluminumandzincalloys· K../13forcopperalloyssuchasbronzeorbrass· Free-radiatingheatingelementsonsupporttubesforlongservicelifeandsimple

replacement· Twelvemonthswarrantyonheatingelements· Multi-layerinsulationforoptimumenergyefficiencyandlowexternalwall

temperatures· Incl.crucible· Electro-hydraulictiltingdevicewithsafetwo-handoperationonthefurnace· Uniformandprecisepouringduetooptimumpivotpoint· Emergencyoutletforsafedrainingofthemeltincaseofcruciblebreakage· Noexhaustgasdischargeneeded· Integratedsafetysystemwhichcontinuestooperatethefurnaceatreduced

powerincaseofmalfunctioninthethermocouple,inordertopreventthefreezingofthemelt

· Over-temperaturelimiterinfurnacechamberforprotectionagainstoverheating.Thelimiterswitchestheheatingoffwhenthesetlimittemperatureisreached,andonlyswitchesitbackonafterthetemperaturehasfallenagain.

· Low-maintenancefurnacechambercontrolwithtemperaturemeasurementbehindthecrucible

Additional Equipment

· Safetyfence· Workplatformforeasycharging· Collectingpanundertheemergencyoutletseepage39· Cruciblebreakagemonitorwithvisualandaudiblesignal(onlyformodelsK../12)· Bathcontrolwiththermocouplesinthefurnacechamberandinthemelt.The

furnacetemperatureiscontrolledthroughthemelt.Temperatureovershootsarereduced,thusthequalityofthemeltisimproved

· Heatingsystemoperatedthroughthyristors· Multi-stepswitchingofthefurnaceheat(seepage43)· Modelswithincreasedheatingpower· ProcesscontrolanddocumentationviaNaberthermControlCenter(NCC)for

monitoring,documentationandcontrolseepage42

10

Threetiltingfurnaceswithworkplatformformeltingofaluminum

ChargingoftransportladlewithtiltingfurnaceK360/12

Model Tmaxfurnace

Tmaxmeltbath

Crucible Capacityinkg

Heatingpower

Meltingperformance3,6

inkg/h

Consumptionmelting6

kWh/kg

Consumptionholding

Lidclosed/open

Outerdimensions5

inmmWeight

°C °C Al Zn Cu inkW4 Al Al kWh/h W D H inkgK 80/12 1200 1050 TP287 180 470 - 50 126¹ 0.4¹ 4/10¹ 2050 1520 1580 1750K 150/12 1200 1050 TP412 330 870 - 60 147¹ 0.4¹ 5/12¹ 2120 1600 1860 2350K 180/12 1200 1050 TP412H 370 980 - 60 160¹ 0.4¹ 5/12¹ 2120 1600 1860 2450K 240/12 1200 1050 TP587 570 1500 - 80 180¹ 0.4¹ 8/17¹ 2260 1760 1860 2800K 360/12 1200 1050 TBN800 750 - - 100 260¹ 0.4¹ 11/20¹ 2370 1810 1950 3500K 400/12 1200 1050 TBN1100 1050 - - 126 295¹ 0.4¹ 12/22¹ 2370 1930 2100 3700

Cu CuK 10/13 1300 1150 A70 20 50 70 16 472 0.32 5/82 1890 1240 1440 1000K 20/13 1300 1150 A150 45 120 150 20 632 0.32 5/82 1890 1400 1460 1300K 40/13 1300 1150 A300 90 240 300 26 842 0.32 5/82 2000 1450 1540 1650K 80/13 1300 1150 TP287 180 470 550 50 1902 0.32 6/112 2050 1520 1580 1950¹Alat700°C2CuZnat1000°C3Thespecifiedmeltingperformancesaremaximumvalues.Inpractice,approx.80%areachieved.4Dependingonfurnacedesignconnectedloadmightbehigher5Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.6Valuesforothermaterials,e.g.zinc,onrequest

TiltingfurnaceK40/13withextendedspout(sculpture foundry Knaak)

Fillingamouldwithliquidbronze(photographer Andrea Künstle)

11

Tilting Furnaces KB Gas-Fired,forMeltingandHolding

Thegas-firedoroil-heatedtiltingfurnacesintheKBproductlinesprovideforhighmeltingperformance,makingthemidealformeltingoperations.Theuseofhigh-qualityinsulationmaterialsresultsinverylowenergyconsumption.Designedwithanexhaustventoverthecrucibleedge,thesetiltingfurnacesachieveveryhighmeltingratesandoptimumenergyefficiency.

TiltingfurnaceKB400/12withexhaustgasdischargeoverthecrucibleedge

Standard Equipment for all Tilting Furnaces

· KB../12foraluminumandzincalloys· KB../14forcopperalloyssuchasbronzeorbrass· Modernandpowerfultwo-stageburnerforhighmeltingcapacityandlow

maintenanceoperation· Fuelheatingwitheithergasoroil· Exhaustgasdischargeoverthecrucibleedgeseepage6· Multi-layerinsulationforoptimumenergyefficiencyandlowexternalwall

temperatures· Incl.crucible· Electro-hydraulictiltingdevicewithsafetwo-handoperationonthefurnace· Uniformandprecisepouringduetooptimumpivotpoint· Emergencyoutletforsafedischargeofthemeltincaseofacruciblebreak· Integratedsafetysystemwhichcontinuestooperatethefurnaceatreduced


· Over-temperaturelimiterforthefurnacechamberwithautomaticresettoprotectagainstover-temperature.Thelimitcontrollerswitchesofftheheatingwhenthepre-setlimittemperaturehasbeenreachedanddoesnotswitchitonagainuntilthetemperaturefallsbelowthesettingagain.


Standard Equipment for Tilting Furnaces KB ../14

· Insulationwithanadditionalwear-and-tearlayermadeofcopper-resistantrefractoryconcrete

Additional Equipment for all Tilting Furnaces

· Safetyfence· Workplatformorplatformforeasiercharging· Collectingpanundertheemergencyoutletseepage39· Informationonotheraccessoriesseepage38-39

Additional Equipment for Tilting Furnaces KB ../12

· Sideexhaustgasdischargeincludingcoverseepages7· Insulatedexhaustgasdiverterconnectingpiece(exhaustflue)forside-wall

exhaustgasventtoaconnectedcustomersuctionsystem· Cruciblebreakagemonitoringwithopticalandacousticsignal· SMS-alarmmessageincaseofcruciblebreakage· Bathcontrolsystem(onlywhenequippedwithsideexhaustgasdischarge)see

page40· ProcesscontrolanddocumentationviaNaberthermControlCenter(NCC)for

monitoring,documentationandcontrolseepage42MeltingfurnaceplantconsistingoftwotiltingfurnacesKB360/12withsideexhaustgasdischargeandoneworkplatform

12

Hydraulicsystemwithflameresistanthydraulicfluid Two-stageburner,mountedonfurnaceframe Castcopperalloy

Model Tmaxfurnace

Tmaxmeltbath


Burneroutput


inkg/h

Consumptionmelting6

kWh/kg

Consumptionholding

Lidclosed

Outerdimensions4

inmmWeight

°C °C Al Zn Cu kW Al Al kWh/h W5 D H inkg

KB 80/12 1200 1050 TP287 180 470 - 300 2201 1.3-1.51 10 2730 1530 1680 2100KB150/12 1200 1050 TP412 330 870 - 300 2401 1.0-1.31 11 2830 1630 1880 2600KB180/12 1200 1050 TP412H 370 970 - 300 2601 1.0-1.31 13 2830 1630 1980 2800KB240/12 1200 1050 TP587 570 1500 - 390 4001 1.0-1.31 15 3120 1840 1980 3100KB360/12 1200 1050 TBN800 750 - - 450 4201 1.0-1.31 17 3170 1890 2080 3300KB400/12 1200 1050 TBN1100 1000 - - 450 4501 1.0-1.31 19 3170 1890 2150 3600

Cu CuKB 40/14 1400 1250 R400/TP982 - - 400 400 3302 1.0-1.32 22 2710 1530 1550 2400KB 60/14 1400 1250 R500 - - 500 400 3602 1.0-1.32 25 2710 1530 1550 2700KB 80/14 1400 1250 R600 - - 600 400 3802 1.0-1.32 25 2710 1530 1710 34001Alat700°C2CuZnat1000°C3Thestatedmeltingperformancesaremaximumvalues.Dailyoperationcomesuptoroughly80%.4Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.5Incl.burnerandhydraulicsystem6Valuesforothermaterials,e.g.zinc,onrequest

TiltingfurnaceKB150/12inproduction

13

Thefuel-heatedtiltingfurnaceswithrecuperativeburnerprovideforoptimumenergyutilizationcombinedwithveryhighmeltquality.Fittedwithaburnersystemincludingheat-recoverysystemtheenergyefficiencyoffuel-heatedtiltingfurnaceswiththesideexhaustgasdischargeissignificantlyimproved.

Dependingonutilizationtheexhaustgasesfromthecruciblefurnaceareguidedthroughaheatexchangerinordertopreheatthecombustionairfortheburner.Thesystemprovidesforenergysavingsofupto25%comparedtoconventionalfuel-heatedtiltingfurnaceswithsideexhaustgasdischarge.Thehigherpurchasecostsareamortizedwithinashorttime.

TheKBRseriesisrecommendedwhenbothhighmeltqualityrequirementsandhighenergyefficiencyarerequired,andthespeedofthemeltingprocessisofsecondaryinterest.Ifthefastestpossiblemeltingrateisimportantfortheprocessandaparticularlyhighqualityofthemeltisofsecondaryimportance,aconventionaltiltingfurnaceKBwithexhaustductingovertheedgeofthecrucible(seepage6)isrecommended.

Tilting Furnaces KBR with Recuperative Burner Gas-Fired,forMeltingandHoldingofAluminum

Model Tmaxfurnace

Tmaxmeltbath


Burneroutput

Meltingperformance2

inkg/hConsumption

meltinginkWh/kgConsumption

holdingLidclosed

Outerdimensions3

inmmWeight

°C °C Al kW Al Al kWh/h W4 D H inkgKBR240/11 1100 950 TP587 570 390 3201 1.1-1.41 13 2580 2300 1980 3600KBR360/11 1100 950 TBN800 750 450 3401 1.1-1.41 15 2580 2350 2080 3800KBR400/11 1100 950 TBN1100 1000 450 3601 1.1-1.41 16 2580 2350 2150 41001Alat700°C2Thestatedmeltingperformancesaremaximumvalues.Dailyoperationcomesuptoroughly80%.3Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.4Incl.burner

TiltingfurnaceKBR240/11

TiltingfurnaceKBR240/11duringfillingofatransportladle

Standard Equipment as KB Models, but

· Heatexchangerintheexhaustgasducttopreheatthecombustionairfortheburners

· Energysavingsofupto25%incomparisontootherfuel-heatedmeltingfurnacesfeaturingside-wallexhaustgasvents

· Sideexhaustgasdischarge- Lowburn-offprovidesforhighqualitymelt- Lowhydrogenabsorptionbythemelt- Lowheatexposurefortheoperatorintheareaabovethecrucible

· Max.furnacetemperatureof1100°Cformeltbathtemperaturesupto950°C· Requiredminimumgaspressureatfullload:80mbar

Insulatedconnectingpieceforside-wallexhaustgasventtoaconnectedcustomersuctionsystem

Meltingthermocouple

14

SiC Rod Heated Tilting Furnace/Cupola Melting Furnace

Product Videos Melting Furnaces

ChargingoftransportladlewithtiltingfurnaceK360/12

Scanforproductvideo„Tiltingfurnaceforaluminum“

TiltingfurnaceKB360/12andtransportableholdingfurnaceTM150/11

TiltingfurnaceKC80/14

Typicalsolutionforflexiblepremelting.Severalelectrictiltingfurnaces,formeltingofpartlydifferentalloys,andsubsequenttransferofthemelttothecastinglocationbymeansofacranetransportladle.Forfurtherinformationonthisfurnaceseries,alsoseepage10.

Tilting Furnace for Aluminum

Scanforproductvideo„Tiltingfurnaceforpreciousmetals“

Fastmeltinginthegas-firedtiltingfurnaceandsubsequentfillingoftransportableholdingfurnaces.Byfillingtheholdingfurnacedirectlyatthepremelter,thenumberofrefillingoperationscanbekeptlow.Thishasapositiveeffectonbothenergyefficiencyandmeltquality.Formoreinformationonthesefurnaces,alsoseepage12andpage25.

Tilting Furnace and Transportable Holding Furnace

Scanforproductvideo„TiltingfurnaceKB360/12andtransportableholdingfurnaceTM150/11“

TheSiCrod-heatedfurnaceoftheKC/TCseriesshownhereischaracterizedbyitshighmaximumtemperatureandthusalsoenablesthemeltingofalloyswithparticularlyhighcastingtemperatures,suchasaluminumbronzeorcertainpreciousmetals.

15

Tilting Furnace KC SiC-Rod-Heated,forMelting

TheelectricallyheatedtiltingfurnacesoftheKCproductlinesarecharacterizedbyahighermaximaltemperaturethanachievablewithwireheatedmeltingfurnaces.Thisallowsforprocessingofdemandingcopperalloyssuchasaluminumbronze.Thesefurnacesaredesignedforpermanentoperationatworkingtemperatures.


Standard Equipment

· Melttemperaturesupto1320°C· SymmetricalheatingviapowerfulSiCrods· SiC-Crucible· Simpleexchangeofindividualheatingelements· Heatoperationbythyistorsinphase-anglemodewithperformancecontrol:

TheresistanceoftheSiCrodschangeswithtemperatureandage.Performancecontrolensuresconstantpowerofheatingirrespectivetotheconditionoftheheatingelements.

· Multi-layerinsulationforoptimumenergyefficiencyandlowexternalwalltemperatures

· Electro-hydraulictiltingdevicewithsafetwo-handoperationonthefurnace· Uniformandprecisepouringduetooptimumpivotpoint· Emergencyoutletforsafedrainingofthemeltincaseofcruciblebreakage· ExclusiveuseofinsulationmaterialswithoutcategorizationaccordingtoEC

RegulationNo1272/2008(CLP)· Over-temperaturelimiterinfurnacechamberforprotectionagainstoverheating.

Thelimiterswitchestheheatingoffwhenthesetlimittemperatureisreached,andonlyswitchesitbackonafterthetemperaturehasfallenagain.



· Additionalheatingtransformersprovideforsignificantreductionoftheconnectedload

· Safetyfence· Workplatformforsimplifiedloading· ProcesscontrolanddocumentationviaNaberthermControlCenter(NCC)for

monitoring,documentationandcontrolseepage42· Forinformationonotheraccessoriesseepage38-39


16

HeatedonbothsidesbyhighperformanceSiCrods

Model Tmaxfurnace

Tmaxmeltbath


Heatingpower Connectedload Meltingperformance3

inkg/hOuterdimensions4inmm Weight

°C °C Cu inkW1 inkW Cu W D H inkgKC 20/14 1450 1320 A150 150 36 69 1202 1710 1900 1050 1500KC 40/14 1450 1320 A300 300 36 69 1202 1770 1900 1100 1600KC 80/14 1450 1320 TPC287 550 48 94 1802 1880 1970 1160 1900KC150/14 1450 1320 TPC412 1000 66 112 2202 2000 2070 1300 2700KC180/14 1450 1320 TPC412H 1150 99 187 2302 2000 2070 1500 30001Reductionofconnectedloadbyoptionalheatingtransformers2CuZnat1000°C3Thespecifiedmeltingperformancesaremaximumvalues.Inpractice,approx.80%areachieved.4Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.

Switchgearwiththyristorsinphaseangleoperationforeconomicpowerconsumption

Swinglidwithgoodsealingtocollarplatetoavoidheatlossoverthecrucibleopening

TiltingfurnaceKC80/14duringcasting

17

Bale-outfurnacesaresuitableformeltingandholdingandarecharacterizedbygoodenergyefficiency.Dependingonthemodel,foraluminum,zincorcopperalloys.

Low-maintenancefurnacechambercontrolwithtemperaturemeasurementbehindthecrucible

Multi-layerinsulationforoptimumenergyefficiencyandlowexternalwalltemperatures

ExclusiveuseofinsulationmaterialswithoutcategorizationaccordingtoECRegulationNo1272/2008(CLP)

Over-temperaturelimiterinfurnacechamberforprotectionagainstoverheating.Thelimiterswitchestheheatingoffwhenthesetlimittemperatureisreached,andonlyswitchesitbackonafterthetemperaturehasfallenagain.

Definedapplicationwithintheconstraintsoftheoperatinginstructions

Asadditionalequipment:ProcesscontrolanddocumentationviaNaberthermControlCenter(NCC)formonitoring,documentationandcontrol

Bale-Out Furnaces

18


Bale-outfurnacesT T 20

Bale-outfurnacesTB TB 22

Bale-outfurnacesTBRwithrecuperativeburner TBR 24

Transportablebale-outfurnacesTM TM 25

Bale-outfurnacesTC TC 26

19

Bale-Out Furnaces T ElectricallyHeated,forMeltingandHolding

Whetherinmanualpouringoperationorintegratedinanautomatedcastingcell,theelectricallyheatedtiltingfurnacesarecharacterizedbyverygoodmeltquality,optimumenergyefficiencyandlow-maintenanceoperation.Thesefurnacesareavailablewithreducedconnectedloadforonlyholdingofaluminumalloysorwithincreasedpowerforholdingandmeltingasallrounders.

Bale-outfurnaceT110/11

Bale-outfurnaceT800/11

Standard Equipment

· T../10forholdingaluminumalloys· T../11formeltingandholdingaluminumandzincalloys· T../13formeltingandholdingcopperalloyssuchasbronzeorbrass· Freeradiatingheatingelementsarrangedonfoursidesonsupporttubesprovide

forlongservicelifeandeasyreplacement· Twelvemonthswarrantyonheatingelements· Highmeltingperformancewithtemperatureuniformityinthemelt· Multi-layerinsulationforoptimumenergyefficiencyandlowexternalwall

temperatures· Emergencyoutletforsafedrainingofthemeltincaseofcruciblebreakage· Noexhaustgasdischargeneeded· Integratedsafetysystemwhichcontinuestooperatethefurnaceatreduced





· Crucibleofclay-graphiteorSiC· Collectingpanundertheemergencyoutletseepage39· Cruciblebreakagemonitorwithvisualandaudiblesignal(notforT../13)· Bathcontrolwiththermocouplesinthefurnacechamberandinthemelt(notfor

T../13).Thefurnacetemperatureiscontrolledthroughthemelt.Temperatureovershootsarereduced,thusthequalityofthemeltisimproved

· Heatingsystemoperatedthroughthyristors· Multi-stepswitchingofthefurnaceheat(seepage43)· Higherelectricalratingstoincreasemeltingperformance· Workplatformforeaseofcharging· AlarmmessageviaSMS,e.g.intheeventofcruciblebreakage· ProcesscontrolanddocumentationviaNaberthermControlCenter(NCC)for


20

Foursideheatingforexcellenttemperatureuniformity Manualladlingfromabale-outfurnaceT80/10

Model Tmaxfurnace

Tmaxmeltbath


Heatingpower


Consumptionmelting6

Consumptionholding

Lidclosed/open

Outerdimensions5inmm Weight

°C °C Al Zn Cu inkW4 inkg/h kWh/kg kWh/h W D H inkgT 80/10 1000 800 BU200 200 - - 20 - - 4/91 1110 1110 940 1050T 110/10 1000 800 BU300 300 - - 26 - - 5/101 1200 1200 1040 1240T 150/10 1000 800 BU350 350 - - 38 - - 5/101 1200 1200 1140 1330T 180/10 1000 800 BU500 500 - - 42 - - 7/151 1370 1370 1250 1400T 240/10 1000 800 BU600 600 - - 50 - - 7/151 1370 1370 1350 1530T 360/10 1000 800 BN800 800 - - 50 - - 8/171 1510 1510 1490 2000T 450/10 1000 800 BU1800H830 1040 - - 50 - - 13/201 1685 1685 1360 2400T 560/10 1000 800 BU1800H1000 1400 - - 50 - - 13/231 1685 1685 1530 2550T 800/10 1000 800 BU1800 1800 - - 70 - - 15/251 1685 1685 1830 2800

Al AlT 10/11 1100 950 A70 20 50 - 16 321 0.41 3/51 860 860 790 550T 20/11 1100 950 A150 45 110 - 20 421 0.41 3/61 940 940 790 650T 40/11 1100 950 A300 90 230 - 26 581 0.41 3/71 1010 1010 880 750T 80/11 1100 950 BU200 200 520 50 1261 0.41 4/91 1110 1110 940 1050T 110/11 1100 950 BU300 300 790 - 60 1361 0.41 5/101 1200 1200 1040 1240T 150/11 1100 950 BU350 350 920 - 60 1471 0.41 5/101 1200 1200 1140 1330T 180/11 1100 950 BU500 500 1320 - 70 1681 0.41 7/151 1370 1370 1250 1400T 240/11 1100 950 BU600 600 1580 - 80 1801 0.41 7/151 1370 1370 1350 1530T 360/11 1100 950 BN800 800 2110 - 110 2001 0.41 8/171 1510 1510 1490 2000T 450/11 1100 950 BU1800H830 1040 2740 - 110 2001 0.41 13/201 1685 1685 1360 2400T 560/11 1100 950 BU1800H1000 1400 3690 - 110 2201 0.41 13/231 1685 1685 1530 2550T 800/11 1100 950 BU1800 1800 4750 - 140 2401 0.41 15/251 1685 1685 1830 2800

Cu CuT 10/13 1300 1150 A70 20 - 70 16 472 0.32 5/82 900 900 890 650T 20/13 1300 1150 A150 45 - 150 20 632 0.32 5/102 980 980 890 780T 40/13 1300 1150 A300 90 - 300 26 842 0.32 5/122 1050 1050 970 960T 80/13 1300 1150 BU200 200 - 650 50 1902 0.32 5/152 1150 1150 1030 12001Alat700°C 2CuZnat1000°C3Thespecifiedmeltingperformancesaremaximumvalues.Inpractice,approx.80%areachieved.Valuesforothermaterials,e.g.zinc,onrequest.4Dependingonfurnacedesignconnectedloadmightbehigher5Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.6Valuesforothermaterials,e.g.zinc,onrequest

Bale-outfurnaceT80/13forgunmetalinasandfoundryshop

Bale-outofbale-outfurnacewithrobot

21

Bale-Out Furnaces TB Gas-Fired,forMeltingandHolding

Thegas-firedoroil-heatedbale-outfurnacesoftheTBproductlinesprovideforhighmeltingperformance.Theuseofmodernburnersystems,optimizedpressuresandflameguideinthefurnaceaswellastheprocessingofhigh-qualityinsulationmaterialsresultinverylowenergyconsumption.

Bale-outfurnaceTB20/14forbronzemeltingwithsideexhaustgasdischargeandswivelingcollarplateforcruciblepulling

Bale-outfurnaceTB20/14

Standard Equipment for all Bale-Out Furnaces

· TB../12foraluminumandzincalloys· TB../14forcopperalloyssuchasbronzeorbrass· Modernandpowerfultwo-stageburnerforhighmeltingcapacityandlow

maintenanceoperation· Fuelheatingwitheithergasoroil· Multi-layerinsulationforoptimumenergyefficiencyandlowexternalwall

temperatures· Emergencyoutletforsafedischargeofthemeltincaseofacruciblebreak· Integratedsafetysystemwhichcontinuestooperatethefurnaceatreduced




Standard Equipment for Bale-Out Furnaces TB ../12

· Sideexhaustgasdischargeresultsinahighqualityofthemelt· Swinglid

Standard Equipment for Bale-Out Furnaces TB ../14

· Insulationwithanadditionalwear-and-tearlayermadeofcopper-resistantrefractoryconcrete

· Exhaustgasdischargeoverthecrucibleedgeprovidesforhighmeltingcapacity· Swingingcollarplateforcruciblepullingforbale-outfurnacestoTB10/14-

TB20/14(notpossibleforlargermodels)

Additional Equipment for Bale-Out Furnaces TB ../12

· Cruciblebreakagemonitoringwithopticalandacousticsignal· SMS-alarmmessageincaseofcruciblebreakage· Bathcontrolsystem

22

Thermocoupleformeltbathcontrol Emergencyoutletforsafemeltdischargeincaseofcruciblebreak

Model Tmaxfurnace

Tmaxmeltbath


Burneroutput


Consumptionmelting5

Consumptionholding

Outerdimensions4

inmmWeight

inkg/h kWh/kg kWh/h°C °C Al Zn Cu kW Al Al Lidclosed W D H inkg

TB 80/12 1200 1050 BU200 200 520 - 180 1401 1.3-1.51 10 1200 1870 1240 900TB100/12 1200 1050 BU250 250 660 - 180 1401 1.3-1.51 11 1310 1980 1380 1000TB 110/12 1200 1050 BU300 300 790 - 210 1501 1.3-1.51 13 1310 1980 1510 1200TB150/12 1200 1050 BU350 350 920 - 300 2201 1.3-1.51 15 1310 1980 1550 1400TB180/12 1200 1050 BU500 500 1320 - 300 2701 1.3-1.51 17 1450 2140 1560 1700TB240/12 1200 1050 BU600 600 1580 - 390 3301 1.3-1.51 19 1490 2180 1700 1900TB360/12 1200 1050 BN800 800 2110 - 400 3501 1.3-1.51 20 1590 2280 1800 2000TB400/12 1200 1050 BN900 900 2370 - 400 3501 1.3-1.51 22 1590 2280 1900 2100TB500/12 1200 1050 BU1210 1200 3160 - 400 3501 1.3-1.51 23 1690 2380 1850 2300TB600/12 1200 1050 BU1310 1300 3430 - 500 4201 1.3-1.51 25 1690 2380 2000 2400TB650/12 1200 1050 BP1000 1400 3690 - 500 4201 1.3-1.51 26 1760 2450 1630 2300TB700/12 1200 1050 BU1510 1500 3960 - 500 4201 1.3-1.51 28 1690 2380 2120 2600TB800/12 1200 1050 BU1800 1800 4750 - 500 4401 1.3-1.51 30 1760 2450 2100 2800

Cu Cu WithoutlidTB 10/14 1400 1250 A100 - - 100 210 902 1.0-1.32 16 980 1590 1190 1000TB 20/14 1400 1250 A150 - - 150 210 1002 1.0-1.32 17 1080 1870 1310 1250TB 40/14 1400 1250 A400 - - 400 300 3002 1.0-1.32 23 1210 2000 1460 1500TB 60/14 1400 1250 A500 - - 500 320 3202 1.0-1.32 26 1210 2000 1510 1600TB 80/14 1400 1250 A600 - - 600 320 3202 1.0-1.32 29 1260 2050 1540 17501Alat700°C2CuZnat1000°C3Thestatedmeltingperformancesaremaximumvalues.Dailyoperationcomesuptoroughly80%.4Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.5Valuesforothermaterials,e.g.zinc,onrequest

Bale-outfurnaceTB20/14inapitwithexhaustgasdischargeoverthecruciblerimeandswivelingcollarplateforcruciblepulling

Bale-outfurnaceTB240/12withlateralexhaustgasdischarge

23

Burnerwithgassupplysystem

Bale-Out Furnaces TBR with Recuperative Burner Gas-Fired,forMeltingandHolding

Thefuel-heatedcruciblefurnacesintheTBRproductlinefittedwiththesideexhaustgasdischargeprovideforoptimumenergyutilizationcombinedwithhighestqualitymelt.Fittedwithaburnersystemincludingheat-recoverysystemusingarecuperativeburner,theenergyefficiencyofordinaryfuel-heatedmeltingfurnacesissignificantlyimproved.Dependingonutilizationthehotexhaustgasesfromthecruciblefurnaceareguidedthroughaheatexchangerinordertopreheatthecombustionairfortheburner.Thesystemprovidesforenergysavingsofupto25%comparedtoordinaryfuel-heatedfurnaceswithsideexhaustgasdischarge.Thehigherpurchasecostsareamortizedwithinashorttime.

Model Tmaxfurnace

Tmaxmeltbath


Burneroutput

Meltingperformance2

kg/hConsumptionmelting

kWh/kgConsumption

holdinglidclosed

°C °C Al kW Al Al kWh/hTBR 80/11 1100 950 BU200 200 180 1401 1.0-1.11 8.0TBR 100/11 1100 950 BU250 250 180 1401 1.0-1.11 8.8TBR 110/11 1100 950 BU300 300 210 1501 1.0-1.11 10.4TBR 150/11 1100 950 BU350 350 240 2201 1.0-1.11 12.0TBR 180/11 1100 950 BU500 500 300 2701 1.0-1.11 13.6TBR 240/11 1100 950 BU600 600 320 3301 1.0-1.11 15.2TBR 360/11 1100 950 BU800 800 320 3501 1.0-1.11 16.01Alat700°C2Thestatedmeltingperformancesaremaximumvalues.Dailyoperationcomesuptoroughly80%.

Heatexchangerintheexhaustgasduct TwocruciblefurmacesTBR100/11inproduction

CruciblefurnaceTBR110/11

Standard Equipment as TB Models, but

· Heatexchangerintheexhaustgasducttopreheatthecombustionairfortheburners

· Energysavingsofupto25%incomparisontootherfuel-heatedmeltingfurnacesfeaturingside-wallexhaustgasvents

· Maximumfurnacechambertemperature1100°C,formeltbathtemperaturesupto950°C

· Requiredmin.gaspressurewithfullload:70mbar· Onlygasfiringpossible,nooil· Over-temperaturelimiterinfurnacechamberforprotectionagainstoverheating.



24

Transportable Bale-Out Furnaces TM ElectricallyHeated,forHoldingandTransportAluminum

Thetransportablebale-outfurnacesoftheTMproductlinesweredevelopedespeciallyforuseatdifferentpouringlocations.Thecylindrical,verystablefurnacehousing,theveryhigh-qualityinsulationandthemeander-shapeheatingelementsarethespecialfeaturesofthisfurnacefamily.Thefurnacesaredesignedtobetransportedbyforklifttruckandcomewithaplug-inconnectiontothecontrolgear.Withaforklifttruckthefurnacecanbetransportedtothepre-meltfurnaceforfilling.Duetothefillingofthebale-outfurnacedirectlyatthepremeltingfurnace,theotherwisenecessaryintermediatetransportbymeansofatransportladleandanadditionalfillingprocesscanbeomitted.Thishasapositiveeffectonbothenergyefficiencyandmeltquality.

Meanderheatingelements Plugsocketonthefurnaceforthecableconnectiontotheswitchgearandcontrolbox

Model Tmaxfurnace

Tmaxmeltbath


Heatingpower Consumptionholding

Lidclosed/open

Outerdimensions3

inmm

°C °C Ø H Al inkW2 kWh/h1 W D HTM80/10 1000 800 BU200 200 21 4/9 1000 1100 1150TM150/10 1000 800 875 600 350 36 5/10 1320 1440 1150TM240/10 1000 800 BU600 600 42 7/15 1220 1340 1450TM310/10 1000 800 1170 580 770 42 8/17 1650 1730 12001Alat700°C2Dependingonfurnacedesignconnectedloadmightbehigher3Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.

Forkliftentrywithdampers

Standard Equipment

· Tmax1000°C,idealforholdingofaluminumalloys· Cylindrical,highlystablefurnacehousing· Damperslotsunderthefurnaceforsafeforklifttransportationofthefurnacewith

themeltinsidethefoundry· All-roundheatingprovidedbymeander-shapeheatingelements· Plugconnectiononthefurnaceforeasydisconnectionoftheconnectingcableto

theswitchgear· Heatingcontrolledusinglong-lastingsolid-state-relays· Insulationconstructedinmultiplelayerswithlightweightrefractorybricksonthe

hotface· Emergencyoutletforsafedischargeofthemeltincaseofacruciblebreak· Noexhaustgasventnecessary· Crucibleinstandarddesignnotincluded· Over-temperaturelimiterinfurnacechamberforprotectionagainstoverheating.



AdditionalEquipmentlikeModelsTseepage20Transportablebale-outfurnaceTM150/10

25

Bale-Out Furnace TC SiC-Rod-Heated,forMelting

HeatedonbothsidesbyhighperformanceSiCrods

Theelectricallyheatedbale-outfurnacesoftheTCproductlinesarecharacterizedbyahighermaximaltemperaturethanachievablewithwireheatedmeltingfurnaces.Thisallowsforprocessingofdemandingcopperalloyssuchasaluminumbronze.Thesefurnacesaredesignedforpermanentoperationatworkingtemperatures.

Model Tmaxfurnace

Tmaxmeltbath


Heatingpower Connectedload Meltingperformance3

inkg/hOuterdimensions4inmm Weight

°C °C Cu inkW1 inkW Cu W D H inkgTC 20/14 1450 1320 A150 150 36 69 1202 1200 1250 930 830TC 40/14 1450 1320 A300 300 36 69 1202 1260 1250 1020 950TC 80/14 1450 1320 BU200 650 48 94 1802 1360 1350 1080 1050TC150/14 1450 1320 BU300 1000 66 112 2202 1450 1320 1300 13001Reductionofconnectedloadbyoptionalheatingtransformers2CuZnat1000°C3Thespecifiedmeltingperformancesaremaximumvalues.Inpractice,approx.80%areachieved.4Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.

Switchgearwiththyristorsinphaseangleoperationforeconomicpowerconsumption

Swinglidwithgoodsealingtocollarplatetoavoidheatlossoverthecrucibleopening

Bale-outfurnaceTC80/14

Standard Equipment

· Melttemperaturesupto1320°C· SymmetricalheatingviapowerfulSiCrods· Simpleexchangeofindividualheatingelements· Heatoperationbythyistorsinphase-anglemodewithperformancecontrol:

TheresistanceoftheSiCrodschangeswithtemperatureandage.Performancecontrolensuresconstantpowerofheatingirrespectivetotheconditionoftheheatingelements.

· Multi-layerinsulationforoptimumenergyefficiencyandlowexternalwalltemperatures

· Emergencyoutletforsafedrainingofthemeltincaseofcruciblebreakage· ExclusiveuseofinsulationmaterialswithoutcategorizationaccordingtoEC

RegulationNo1272/2008(CLP)· Over-temperaturelimiterinfurnacechamberforprotectionagainstoverheating.




· Additionalheatingtransformersprovideforsignificantreductionoftheconnectedload

· Workplatformforsimplifiedloading· ProcesscontrolanddocumentationviaNaberthermControlCenter(NCC)for


26

Furnaces for Special Applications

28


BathfurnacesB B 30

LaboratorytiltingfurnaceK/KC K/KC 31

Meltingfurnacesincustomizeddimensions 32

CleaningfurnaceforrisertubesSRO SRO 35

29

Bath Furnaces B ElectricallyHeated,forHoldingofAluminum

Model Tmaxfurnace

Tmaxmeltbath

Capacityinkg

Heatingpower Consumptionholding

Bale-outopening Outerdimensions2inmm Weight

°C °C Al inkW1 kWh/h mm W D H inkgB120 1000 750 300 11 2 300x300 1900 1150 1160 1900B250 1000 750 600 14 3 380x380 2030 1280 1200 2450B500 1000 750 1200 20 5 430x430 2350 1450 1240 37001Dependingonfurnacedesignconnectedloadmightbehigher2Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.

Thebathfurnaces(withoutcrucibles)havebeenespeciallydevelopedforstationaryholdingoperationindie-castfoundrieswithremovalofthemeltbyabale-outrobot.Thetubofthebathfurnacesislinedwithspeciallong-lifebrick.Themulti-layeredbackinginsulationisdesignedforlowestelectricconnectedload.Thefurnacetubisdividedintothreeinterconnectedchambers.Theheatingproceedsfromthelidintothecenterchamber.Thebale-outopeningsaredimensionedtoenabletherobottobeoptimallyused.Inholdingoperationbathfurnaces,whenusedproperly,providebetterenergyefficiencythanbale-outfurnaces.

BathfurnaceB500

BathfurnaceB120

Inletopeningforfillingwithliquidaluminum Meltingthermocoupleinthebathoftheoutletopening Heatingmountedinthelid,simplereplacementoftheheatingelements

Standard Equipment

· Perfectlysuitedforholdingofaluminum· Heatingmountedinthelid,freelyradiatingfromcarriertubes· Particularlylowenergyconsumptionduetogenerouslydimensioned,multi-layer

insulation· ExclusiveuseofinsulationmaterialswithoutcategorizationaccordingtoEC

RegulationNo1272/2008(CLP)· Veryhighmeltquality,amongotherthingsbecausetheextractionbasinis

connectedtotheheatedmainbasinonlybelowthebathsurface.· Heatingswitchedbylow-maintenancesolid-state-relays· Noexhaustgasdischargeneeded· Temperaturecontrol/measurementinthemeltandinthefurnacechamber· Usefulonlyforholding,notformelting


· Adaptationtodosingpump· Automatedlidopeningforladlingoperation· Ladleopeningadaptedtosizeofladle

30

Laboratory Tilting Furnaces K/KCElectricallyHeated

Thesecompacttiltingfurnacesforthemeltingofnon-ferrousmetalsandalloysareoneofakindandhaveanumberoftechnicaladvantages.Designedastabletopmodels,theycanbeusedformanylaboratoryapplications.Thepracticalcounterbalancedhingewithshockabsorbersandthespout(notforKC4/14)onthefrontofthefurnacemakeexactdosingeasywhenpouringthemelt.Themeltingfurnacesareavailableforfurnacechambertemperaturesof1000°C,1300°C,or1400°C.

TiltingfurnaceK4/10withsteelcrucible,e.g.fortinmelting



Model Tmaxfurnace Tmaxmeltbath Crucible Volume Outerdimensions3inmm Connectedload Weight

°C °Cinkg

inl W D H kW inkgAl CuK1/10 1000 850 A6 1,5 - 0.75 600 710 670 3.0 85K2/10 1000 850 A10 3 - 1.50 600 710 670 3.0 90K4/10 1000 850 A25 7 - 3.00 670 800 710 3.5 110

K1/131 1300 1150 A6 1,5 6 0.75 600 710 670 3.0 85K2/131 1300 1150 A10 3 10 1.50 600 710 670 3.0 90K4/131 1300 1150 A25 7 25 3.00 670 800 710 5.5 110

KC1/142 1400 1250 A6 - 6 0.75 570 630 580 11.0 90KC2/142 1400 1250 A10 - 10 1.50 570 630 580 11.0 95KC4/142 1400 1250 A25 - 25 3.00 670 870 590 22.0 1101Outerdimensionsoffurnace,transformerinseparatehousing(500x570x300mm)2Switchgearandcontrollermountedinafloorstandingcabinet3Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.

Standard Equipment

· Tmax1000°C,1300°C,or1400°C· Cruciblesizesof0.75liters,1.5litersor3liters· Cruciblewithintegratedpouringspoutofclay-graphiteincludedwithdelivery· Additionalspout(notforKC4/14),mountedatthefurnaceforexactpouring· ExclusiveuseofinsulationmaterialswithoutcategorizationaccordingtoEC

RegulationNo1272/2008(CLP)· Compactbench-topdesign,simpleemptyingofcruciblebytiltiingsystemwith

gasdamper· Crucibleforheatingupofmeltingfurnaceinsulatedwithahingedlid,lidopened

whenpouring· ControllerR7(resp.3508forKC)


· Othercrucibletypesavailable,e.g.steel· Designasbale-outfurnacewithouttiltingdevice,e.g.forleadmelting· Over-temperaturelimiterforthefurnacechamberwithautomaticresettoprotect

againstovertemperature.Thelimitcontrollerswitchesofftheheatingwhenthepre-setlimittemperaturehasbeenreachedanddoesnotswitchitonagainuntilthetemperaturefallsbelowthesettingagain.

· Observationholeformelt

Tilting-aidwithdampers

31

TiltingfurnaceK240/12withliftingplatformforchargingandpouringatdifferentlevels

Dependingonthematerialflowandspacerequirementsinafoundry,thechargingheightandpouringheightmayneedtobedifferentforatiltingfurnace.Forinstance,ifloadingisperformedatgroundlevelandthemetalispouredintoamachineatahigherlevel,thenanoptionalelectro-hydraulicliftingplatformcanadjustforthedifference.Theoperationoftheliftingplatformisbymeansofa2handoperationwithamanualthrottlingvalve.Itcanalsobeinterlockedwithothermachineryandbemotordrivenoperated.

Tilting Furnaces with Electrohydraulic Lifting Platforms

Melting Furnaces in Customized Dimensions

Forcontinuousprocesses,multiplecruciblefurnacescanbecombinedonarotarytablesystem.Forexample,whenusingthreefurnaceswitharotationin120°steps,loadingtakesplaceatthefirstspace,de-gassingatthesecondspace,andbale-outatthethird.Thisensuresacontinuoussupplyofliquidmetalatthepouringlocation.Therotarytableisdesignedwithanemergencydrainbelowincaseofcruciblebreakage.

Rotarytablesystemwiththreebale-outfurnacesT150/11

Rotary Table System for Continuous Pouring

32

Steelcruciblewithspecialsuspensionbracketsforhighchargeweight

ThemeltingfurnacesintheKandTproductlinescanbeupgradedwithadaptedelectricalheatingformeltingofheavymetalslikeleadandzinc.Themeltingfurnaceisequippedwithaspecialcrucible,inmostcasesasteelcrucible.Themeltingpoweristailoredtothetypeofmetaltoensureoptimumutilizationofthemeltingfurnace.

TiltingfurnaceK240/11formeltingoflead

Melting Furnaces for Heavy Metals

TiltingfurnaceforheavymetalswithbathcontrolRimsuctionringforconnectiontocustomer‘sexhaustairsystem

Electricallyheatedbale-outfurnacefortinorleadwithrimsuctionringandmeltingbaththermocouple

Electricallyheatedbale-outfurnacewithsteelcrucibleandswivellidfortinorlead

33

TiltingfurnaceK1500/75Sformagnesiumwith1500literscruciblevolume

Foravarietyofprojects,Naberthermhassuppliedmeltingfurnacestobeupgradedbythecustomerforthemeltingofmagnesium.Naberthermsuppliedthetiltingfurnacewithallnecessarycontrolsystemsandthesteelcrucible.Themeltingfurnaceswerecompletedbythecustomerwiththesafetydevices,thepumpsystemsforbale-out,andgassupplysystems.

Melting Furnaces for Magnesium

34

Model Tmax Outerdimensions2inmm Outertube-Ø/ Heated Heating Electrical°C W D H mm length/mm powerinkW1 connection*

SRO170/1000/11 1100 590 640 1700 90 1000 12,0 3-phase1Dependingonfurnacedesignconnectedloadmightbehigher2Externaldimensionsvarywhenfurnaceisequippedwithadditionalequipment.Dimensionsonrequest.*Pleaseseepage43formoreinformationaboutsupplyvoltage

Cleaning Furnace for Riser Tubes SROElectricallyHeatedRisertubesforlow-pressuremeltingfurnacesmustbecleanedinregularintervals.Toremovedepositsthepipemustberemovedfromthefurnaceandheated.Incomparisontoapplyinganopenflametoheatthepipe,theSRO170/1000/11furnaceofferstheadvantagesofveryuniformtubeheating.Thequalityoftheheattreatmentisclearlybetterandthelife-timeoftheriserscanbeextendedwhencleanedregularly.Theheatedrisingtubecanberemovedfromthefurnacehotandreturnedtothelow-pressuremeltingfurnace.

Thefurnaceischargedfromaboveusingacraneprovidedbythecustomer.Locatedinthelowersectionofthefurnaceisasteelcatchdrawerwhichisfilledwithsandorsizingcompound.Therisingtubehangsinthereceptaclewithacraneeyeandthedepositsdripintothedrawer.Designedasadrawer,itcanbeeasilypulledout,emptiedandfilledagain.

Tobepulledwithcraneeyeforrisertubeswithflange

CleaningfurnaceSRO170/1000/11withsuspendedpipe

Standard Equipment

· Tmax1100°C· Chargingopeningwithcollarplateandswinglidonthefurnace.Chargingofthe

risingtubeusingthecustomercrane.· Max.dimensionsoftherisingtube:Length:1000mm,outerdimension90mm

withsingle-sideflangewithanouterdiameterof115mm· ExclusiveuseofinsulationmaterialswithoutcategorizationaccordingtoEC

RegulationNo1272/2008(CLP)· Heatedlength:1000mm· Chargereceptaclewithcraneeyeforholdingsmallerrisers· Steelcatchdraw,filledbythecustomerwithsand,whichcollectsdeposits· Steelcollectordesignedasadrawer· Furnaceonrollers· Switchgearandcontrolequipmentfasteneddirectlytothefurnace· NTLogBasicforNaberthermcontroller:recordingofprocessdatawithUSB-flash

drive


· Designforotherriserdimesionsonrequest· Switchgearonrollers

SteelcollectordesignedasadrawerCleaningfurnaceSRO170/1000/11

35

Accessories and Process Control and Documentation

36

Page

Accessoriesforbale-outandtiltingfurnaces 38

Controlanddocumentationalternativesformeltingfurnaces 40

Standardcontrollers,HiProSystemscontrolanddocumentation 40

Datastoringandvisualization 42

Functionsofthestandardcontroller 43

37

Accessories for Bale-Out and Tilting Furnaces

Crucible Pulling Feature with Swinging Collar Plate

CruciblePullingFeaturewithswingingcollarplate

Chargingfunnelforingots

Charging Funnel for Ingots

Instandardversion,Naberthermcruciblefurnacesarebuiltwithacollarplatefixedtothefurnace.Thebale-outisdonemanuallyorbyrobot.Asadditionalequipment,thesmallermodelsuptoT40/..canbeequippedwithaswingingcollarplatewhichallowscruciblepulling.Topullthecrucible,thecollarplateisswungtotheside,sothattheoperatorhasfreeaccesstothecruciblefromabove.

Thechargingfunnelmadeofstainlesssteel1.4301(304)makeschargingthefurnacemucheasier,especiallywhenmeltingingots.Longingotscanalsobechargedextendingoverthecrucibleedge,andthensink,guided,intothecrucible.Furnaceswhicharedesignedwithacontrolsystemwithnight-timereductioncan,forexample,befilledintheeveningand,onthefollowingmorningacompletemeltisreadyforuse.Thefunnelissuitableforallmeltingfurnaces,electricallyheatedorgas-withasideexhaustgasdischarge.

Cruciblebreakagealarmdeviceundertheemergencyoutletofameltingfurnace

Crucible Breakage Alarm Device for T(B)../12 Models

Naberthermmeltingfurnacesareequippedwithemergencyoutlet.Incaseofcruciblebreakageorleakingmeltthecruciblebreakagealarmdevicewillprovideforawarningassoonasfluidmetalemergesfromtheemergencyoutlet.Thewarningsignalofthealarmisbothoptical,withansignallamp,andacoustic,usingahorn.AsadditionalequipmentitispossibletosendanalarmasSMS-messagetooneormoremobilephones.Oneormorefurnacescanbeconnectedtothemessagingdeviceinparallel.

Ourwiderangeoffurnacesforthefoundrycanbeextendedindividuallyforyourapplicationprocessesbyourextensiverangeofaccessories.Fordetailedinformationorforspecialrequests,pleasecontactus.Withourlongtermexperienceandoneofthelargestengineeringdepartmentsinthefurnaceindustry,wewouldbeverypleasedtoworkwithyouandfindasolutiontailoredtoyourneeds.

38

Pneumatic Lid Opener for Bale-Out Furnaces for Holding

Pneumaticlidopener

WorkplatformfortiltingfurnaceK240/12

Work Platform for Loading for Bale-Out and Tilting Furnaces

ThecruciblefurnacesoftheT..productlinescanbeequippedwithanoptionalpneumaticlidopener.Thepneumaticlidopenerisactivatedbydepressingafootpedal.Optionally,thepneumaticlidopenercanbecontrolledandtriggeredbyanexternalsignaltofullyautomatetheladlingprocess.Thefurnacelidswingstothesideandtheoperatorhasfreeaccesstothecrucible.Thispracticalfeatureincreasesenergyefficiencybecausethefurnaceisonlyopenduringchargingandbale-out.Over50%energysavingscanberealizedwiththepneumaticlidopenervs.analwaysopenfurnace(seetablesforenergyconsumptionforeachmodelofmeltingfurnace,page7).

Forbale-outandtiltingfurnaces,customizedworkplatformsforchargingandservicingcanbeprovidedasadditionalequipment.Thisfeatureisusedtosimplifyaccesstothefurnace,particularlyforlargerfurnacemodels.Theoperatorhasaccesstothetopofthefurnacetochargeingotsorcleanthemelt.

Collecting Pan under the Emergency Outlet

Collectingpanundertheemergencyoutlet

Thebale-outfurnacesarestandardlyeuippedwithaninclinedbottomandanemergencyoutletforliquidmetalincaseofacruciblebreakage.TocollecttheliquidmeltincaseofanemergancythemodelsT..,TB..,K..andKB..canbedeliveredwithasmallbaseframeandacollectingpan.Thepancansafelyreceivefullcruciblevolumeandisequippedwithapull-outhandle.Unncecessaryfoundationworkscanbeavoided.

39

H500

Control and Documentation Alternatives for Melting Furnaces

Furnace Control with Eurotherm 3208 or Eurotherm 3508 and Optional Weekly Timer

Eurotherm3208furnacecontroller

Inthebasicdesign,NaberthermmeltingfurnacesareequippedwithEurotherm3208orEurotherm3508controllers.Thetemperatureismeasuredinsidethefurnacebehindthecrucible.Twosetpointsandoneheatingrampcanbeset.Forexample,thesetpointscouldbetheworkingtemperatureandthelowertemperaturefornightsetback.Adigitalweeklytimercanalsobeusedasanaccessorywhichautomaticallyswitchesbetweenthetwotemperaturesandtheonofffunctionofthefurnace.Theswitchingtimescanbechosenforeachwor-kingday.

Melt Bath Control (cascade control) via PLC and H500 Touch Panel or H700 Touch Panel for Bale -Out and Tilting Furnaces

Inthebasicdesign,thebaleoutandtiltingfurnacesarecontrolledwithathermocoupleinsidethefurnacechamberbehindthecrucible.Forfastheat-uptimes,theoperatorusuallysetsatemperaturethatishigherthanthedesiredmeltbathtemperature.Thiscontrolenablesfastheatingtimesbutalsoresultsintemperatureovershootsinthemeltduetotheindirecttemperaturemeasurement.

Asinoptionthebaleoutandtiltingfurnacescanbeequippedwithameltbathcontrol.Inadditiontothefurnacethermocouple,thetemperatureisalsomeasuredwithathermocoupleinthemelt.Bothtemperaturesarepermanentlyreconciledtoachievetheexactmeltbathtemperature.Ifthemeltbaththermocouplefails,thesystemautomaticallyswitchesovertofurnacecontrol.Thiscontrolconsiderablyimprovesthequalityofthemeltbecauseovershootsareeffectivelyprevented.Thistypeoftemperaturecontrolisespeciallyrecommendedforholdinginordertocontrolthemeltbathtemperatureaspreciselyaspossible.Itisalsothebestchoiceforaquickandautomaticmeltingprocesswithoutanyneedfortheoperatortointerveneinthetemperaturecontrolduringmelting.

Asanalternativetoathermocoupleinthemelt,athermocoupleinapocketinsidethecruciblewallcanalsobeused(specialcruciblewithpocketrequired)whichmeasuresthetemperatureofthecruciblewall.Thisindirectmeasurementisnotaspreciseasmeasuringdirectlyinthemeltandautomaticmeltingisslightlyslower.However,thethermocoupleisinamoreprotectedposition.Thissimplifieschargingofthecrucibleandincreasesthethermocouplelifetime.

ThemeltbathiscontrolledviatheH500PLC-controls(electricallyheatedfurnaces)witha4inch(optional7inch)touchpaneland4operatingbuttonsortheH700-controls(gasfiredfurnaces)witha7inchtouchpanel.Itcombinessimpleoperation,precisecontrol,andextensiveuseroptions.Presentationandprogramentryaredonedirectlybyaverysimpletooperatetouchpanel.Thefunctionsaredisplayedinplaintext.

· Operationwithfurnacechambercontrolormeltbathcontrolalternativelywithcascade· Displayonagraphiccolorscreenwithoverviewofalltemperatures· Veryeasydataentrydirectlyontheoperatingscreen(touchpanel)

Naberthermhasmanyyearsofexperienceinthedesignandconstructionofbothstandardandcustomcontrolalternatives.Allcontrolsareremarkablefortheireaseofuseandeveninthebasicversionhaveawidevarietyoffunctions

Weeklytimertoswitchbetweenmeltingtemperatureandlowertemperature

40

· Weeklytimerforchangingtemperatures,entriesinrealtime· Aprogramwith12segmentscanbesetforeachweekday· Separate,freelyprogrammablepreparationprogram,passwordprotected,e.g.todrythecrucible· Bandalarmwithoverand/orundertemperaturemonitoring· Operatinghourcounter· Integratedsafetysystemthatcontinuesfurnaceoperationatreducedpowerincaseofafracturedmeltbath

thermocoupletopreventthemeltfromsolidifying· Trenddisplayofthefurnacetemperaturesinthepast72hours· Languagechoice

Furnacesalreadyinusecanberetrofittedwithameltbathcontroller.

Furnacecontrol Meltbathcontrolthermocoupleinthemelt

Meltbathcontrolthermocoupleinthepocketofthecruciblewall

Entryoftemperature/timeprogramsintabularformatinseveralsegments

Meltbathcontrolwithathermocoupleinthemelt

Bridging the Melt Bath Controls to Increase Melting Performance and Reduce Melting Times

Ifacompletelyemptycrucibleistoberefilled,thevaluesmeasuredbythemeltbaththermocoupledonotcorrespondtotheactualtemperatureofthecoldmetalsbecausethechargeisnotyetmelted.Apushbuttonisusedtotemporarilyspecifyahigherfurnacetemperaturethantheprogramwouldadjust.Theoperatorselectsthedesiredtime(max.120minutes)andthefurnacetemperature.Whenthetimehasexpired,thecontrollerautomaticallyswitchesbacktomeltbathcontrol.n with Reduced Power

Operation with Reduced Power

Operationwithreducedpowercanbeusedtotemporarilyreducetheconnectedloadofthefurnacewhentheworkingtemperatureisreached.Ifreducedpowerisactivatedandthetemperatureinthefurnaceiswithinorabovethesettemperatureband,partoftheheatingisswitchedofftooperatethefurnacewithreducedpower.

41

NTLogComfort

Other Possible Additional Functions

UserinterfaceControlCenterNCCbasedonPC

NTLogComfortfordatarecordingofaSiemensPLC

Documentation with NTLog

Forprocessdocumentation,theH500-controlscanbeequippedwithNTLogComfort

Withthisextension,theprocessdatacanbestoredinrealtimeonaUSBstick.Noadditionalthermocouplesorsensorsarerequired.Onlythedatathatisavailableinthecontrollerisrecorded.TheCSVdatacanthenbeanalyzedonaPC,eitherviaNTGraphorviaacustomer-suppliedspreadsheetprogram(e.g.MSExcel).Inaddition,acomputerinthesamelocalnetworkcanbeconnectedviaanEthernetconnectionsothatdatacanbewrittendirectlytothiscomputer.

Documentation with NCC

TheH700-controlscanbesupplementedwiththeNaberthermControlCenterSoftware(NCC)includingPC.TheNCC-controlsprovideforaconvenientandcomprehensivedocumentationofthemeltingoperationwiththefollowingdocumentationoptions:

· Allrelevantdata,suchasfurnacetemperature,meltbathtemperature,messages,etc.arealwayssavedasafileeachday

· Thefurnaceisequippedwithanadditionalstartandstopbuttoninaseparatehousing.Whenthebuttonispressed,themeltbathtemperatureisrecordedseparatelyandsavedasafile.Thisenablescustomerchargestobeanalyzedandarchivedseparately.

· Inaddition,thePCcanalsobeusedasanoperatorinterfaceforseveralfurnacessimultaneously· NCCAA(AviationandAutomotive)forapplicationsaccordingtoCQI9,AMSorNADCAP

Manual Program Intervention

Ifthecurrentprogramistobeprolongedandthecontrollershouldnotgotothenextsegment(e.g.continuationofmeltingoperationincaseofovertime),akeyswitchcanbeusedtochangeoverfromprogramoperationtocontrolleroperation.Thecontrollercontinuesworkingwiththepreviouslysettemperatureuntiltheswitchisactivatedagaininordertocontinuewiththeprogram.

Band Alarm under/over Temperature

Abandalarmdisplaystheworkingrangeforcasting.Ifthetemperatureiswithintherange,agreensignallampislitandthemeltcanbeprocessed.Inthisrange,thecontrolleradditionallyprovidesforasignalthatthecustomercanevaluate.Example:Releaseforthefoundryrobot.

FormoreinformationonoperatingoftheNaberthermcontrollers,herearesometutorials:

42

Controller Type Eurotherm3208 Eurotherm3508 H500 H700Availableformodels TM/T/K TB/TBR/KB/KBR TC/KC TC/TM/T/K/KC TM/T/K TB/TBR/KB/KBR

FunctionsFurnacecontrol l l l l l lMeltbathcontrol l l lWeeklytimer ¡ ¡ ¡ l l lBridgingthemeltbathcontroller ¡ ¡ ¡Preparationprogramwith20segments l l lPreparationprogramwitharamp l l lBandalarmunder/overtemperature ¡ ¡ ¡ l l lConnectiontoanoverridingsystem ¡ ¡ ¡ ¡ ¡ ¡Operationwithreducedpower ¡ ¡ ¡ ¡Operatinghourcounter ¡ ¡ ¡ l l lDocumentationwithNTLogComfort ¡DocumentationwithNCC ¡ ¡Manualinterventionintheprogram ¡ ¡ lStandard ¡Option

Additional Equipment for All Electrically Heated Melting Furnaces

Multi-StepSwitch

Mains Voltages for Nabertherm Furnaces1-phase: allfurnacesareavailableformainsvoltagesfrom110V-240Vat50or60Hz.3-phase: allfurnacesareavailableformainsvoltagesfrom200V-240Vor380V-480V,at50or60Hz.Theconnectingratesinthecatalogrefertothestandardfurnacewith400V(3/N/PE)respectively230V(1/N/PE).

Multi-Step Switch for Reduction of Connected Rating

Amulti-stepswitchswitchesoffapartoftheheatingdependingonthepowerofthecorrespondingfurnacemodel.Generally,thefurnacecanbeoperatedatfullloadformelting.Ifthefurnaceisonlyusedinholdingmodetheconnectedratingofthefurnacecanbereducedbyturningoffadefinedpartoftheheatingcapacity,resultinginasignificantcostadvantage.Asanoption,thisfunctioncanbeautomaticallyswitcheddependingontemperature.

Power Management for Reduction of the Electrical Connection Value

Ifseveralcruciblefurnacesareusedtheinstallationofanintelligentpowermanagementcanbetherightchoice.Monitoringallfurnacesthepowermanagementiscontinuouslyreconcilingtheswitch-ontimesoftheheating.Thiseffectivelypreventsallfurnacesfromswitching-onatthesametime.Thepositiveimpactisthatthetotalconnectedratingprovidedbytheenergyprovidercanbesignificantlyreduced.

Switchgear Cooling with Fans or Air-Conditioning

Theswitchgearofourfurnacesisdesignedforenvironmenttemperaturesofupto40°C.Tosecureafailure-freeandlonglastingoperationoftheswitchgearincaseofhighertemperaturestheycanbeequippedwithactivefancoolingorevenwithanair-conditioner.

43

Heat Treatment before and after Casting

44

Seite

Temperingplantsforaluminumandsteel 46

Furnacesforcontinuousprocesses 48

Waxburnout 50

Additivemanufacturing 52

Energyefficiencyconcepts 53

45

Tempering Plants for Aluminum and Steel

Aftercasting,multi-stageheattreatmentisoftennecessary.ForprocessessuchastheT6heattreatmentofaluminum(solutionannealing,quenchingandageing)orthehardeningofsteel,quenchingandtemperingplantsareused.Duetothedesignconsistingofoneormorefurnacesincombinationwithaquenchingtankoracoolingstation,thequenchingandtemperingprocesscanbecarriedoutmanually,semi-automaticallyorevenfullyautomatically.

Drop-Bottom Furnace Plants

General Properties

· Multi-stageheattreatmentofaluminumalloysandsteel· Manual,semi-automatedorevenfullyautomated· Conceptsforhorizontalorverticalmovementofthecharge· Quenchingdelaytimesfromstartofdooropeningofonly5secondspossible· Standardsizesandcustomizedsolutionsavailable· Processdataacquisitionandconsiderationofcommonautomotiveand

aerospacestandardssuchasCQI-9,AMS2750F

Horizontal Quenching and Tempering Plants

Inhorizontalquenchingandtemperingplants,thequenchtankispositionedinfrontofthechamberfurnace.Thechargeistransferredhorizontallyintothefurnacebya2-axismanipulatorand,afterheattreatment,isremovedhotandquenched.Asthemovementtechnologyinthisplantconceptisonlyinthehotfurnacechamberforashorttime,temperaturesofupto1300°Carepossible.

Drop-bottomfurnacesareusedforsolutionannealingandsubsequentrapidquenchingofaluminumalloys.Especiallyforthin-walledaluminumcomponents,quenchingdelaytimesofonly5secondsfromthestartofdooropeningtocompleteimmersioninthequenchingbathcanberealized

Fullyautomaticdrop-bottomfurnaceplant,consistingoftwodrop-bottomfurnaces,movablewaterbathandseveralloadingandunloadingpositions

Drop-bottomfurnacewithfixedquenchingbath

46

Themodulardesignofoursystemsenablesawiderangeofdesignoptionsfortheplantand,withappropriateplanning,alsothepossibilityoflaterexpansion.

Customized Solutions

AutomaticquenchingandtemperingplantN644/S

Mobiledrop-bottomfurnaceforsolutionannealingwithpit-typefurnaceforartificialageingwithfourparkingplaces

Fordetailedinformation,pleasealsoseeourcatalogThermalProcessTechnology.

47

Furnaces for Continuous Processes

ContinuousbeltfurnaceD1000/4000/140/35ASforblackwashdryingonsandcores

Gas-firedrotary-hearthfurnacesforpreheatingofceramicmouldsupto1100°Cincl.thermalpostcombustionforexhaustgascleaning

Forcontinuousprocesseswithfixedcycletimes,suchascoreormolddryingorforpreheatingmoldsininvestmentcasting,continuousfurnacesorrotaryhearthfurnacesareoftentherightchoice.Dependingontheprocess,differentworkingtemperatures,conveyingconceptsandheatingconceptscanbeusedhere.

Theconveyortechnologyistailoredtotherequiredworkingtemperature,geometryandweightofthechargeandtotherequirementsregardingavailablespaceandintegrationintotheprocesschain.Theconveyorspeedandthenumberofcontrolzonesaredefinedbytheprocessspecifications.

Conveyor Concepts

· Conveyorbelt· Metalconveyorbeltwithadjustedmeshgauges· Drivechain· Rollerconveyors· Paternoster· Pusher-type· Rotaryhearth

Heating Systems

· Electricheating,radiationorconvection· Directorindirectgas-fired· Infraredheating· Heatingwiththeuseofexternalheatsources

48

Cyclepush-throughplantforartificialageingofaluminumcastings

Fordetailedinformation,pleasealsoseeourcatalogThermalProcessTechnology.

ContinuouspilgrimstepfurnacesystemNBI70000/15HASforblackwashdryingonsandcores

Basic Configuration Criteria

· Conveyorspeed· Temperatureuniformity· Operatingtemperature· Processcurve· Workspacewidth· Chargeweights· Cycletimeorthroughput· Lengthofchargeanddischargezone· Generatedexhaustgases· SpecificindustrystandardssuchasAMS,CQI-9,FDAetc.· Otherindividualcustomerrequirements

49

Wax Burnout

Forcastingwithlostpatterns,amongotherthings,furnacesareneededtogetthepatternmaterialoutofthemoldinasafewayandtofirethemold.Naberthermalsooffersdifferentsolutionsforthis.

Dewaxing Furnaces, Electrically Heated

Thesefurnacesarespeciallydesignedforlostwaxmeltingwithsubsequentfiringoftheceramicmold.Theelectricallyheatedmodelsareoperatedbelowtheflashpointofthewaxforlostwaxmelting.Thefurnaceshaveaheatedoutletinthebottomofthefurnacechamber,whichtaperstothecenterinafunnelshape.Belowthefurnaceisasealedstainlesssteelcontainerwitharemovabledrawerinwhichthewaxiscollected.Aftercompletionofthemeltingoutprocess,thefurnacecontinuestoheatuptofirethemolds.

Dewaxing Furnaces, Gas-Fired

ThechamberfurnacesoftheNB..BOWAXaresuitableforflash-fireprocessesinwhichthehotfurnaceisloadedwithcastingscrews.Forfastloadingandunloading,thefurnaceisequippedwithapneumaticliftdoor.Afterloading,thewaxliquefiesinaveryshorttime.Thefirstpartoftheoutflowingwaxrunsviatheintegratedpandirectlyintoacollectingbasinunderthefurnaceandissafelycollectedinawaterbasin.Theremainingpartofthewaxevaporatesinthefurnacechamberandissafelyburnedinthedownstreamthermalafterburning.

DewaxingfurnaceN300/WAX

DewaxingfurnaceNB300/BOWAX

50

Burnout of Residual Wax or 3D-Printed Plastic Models

ThechamberfurnacesoftheseriesN(B)..BOareusedforprocesseswithhighorganicquantitiesorhighevaporationrates.Forsafetyreasons,theyhaveanintegratedpilotburnerforignitionoftheflammablecomponentsinmixedgases.Anaccumulationofignitablecomponentsisavoidedandsafeburningisensured.Thesefurnacescanbeusedforresidualdewaxingofcastingscrewsorburnoutof3D-printedplasticmodelswithsubsequentsinteringofthemold.

ChamberfurnaceN650/14BOwithignitionburner

ChamberfurnaceN650/14BO Fordetailedinformation,pleasealsoseeourcatalogAdvancedMaterials.

51

Chamberfurnaceswithgas-supplyboxes

Hot-wallretortfurnaces

Cold-wallretortfurnaces

SeealsocatalogThermalProcessTechnology

Additivemanufacturingallowsforthedirectconversionofdesignconstructionfilesfullyfunctionalobjects.With3D-printingobjectsfrommetals,plastics,ceramics,glass,sandorothermaterialsarebuilt-upinlayersuntiltheyhavereachedtheirfinalshape.

Dependingonthematerial,thelayersareinterconnectedbymeansofabindersystemorbylasertechnology.

Manymethodsofadditivemanufacturingrequiresubsequentheattreatmentofthemanufacturedcomponents.Therequirementsforthefurnacesforheattreatmentdependonthecomponentmaterial,theworkingtemperature,theatmosphereinthefurnaceand,ofcourse,theadditiveproductionprocess.

Naberthermofferssolutionsfromcuringforconservationofthegreenstrengthuptosinteringinvacuumfurnacesinwhichtheobjectsofmetalareannealedorsintered.

Also,concomitantorupstreamprocessesofadditivemanufacturingrequiretheuseofafurnaceinordertoachievethedesiredproductproperties,suchasheattreatmentordryingthepowder.

RetortfurnaceNR150/11forannealingofmetalpartsof3D-printing

OvenTR240fordryingofpowders

ChamberovenKTR2000forcuringafter3D-printing

Compacttubefurnaceforsinteringorannealingunderprotectivegasesorinavacuumafter3D-printing

HT160/17DB200fordebindingandsinte-ringofceramicsafter3D-printing

Additive Manufacturing

Metals

DebindingSintering

Stress-relievingSolutionannealing

Hardening

Ceramics, Glass, Composites, Sand

Plastics

DebindingSintering

DryingCuring

CuringTempering

Drying

under Protective Gases, Reaction Gases or in Vacuum

in Air in Air

Debindinginchamberfurnaceswithaircirculation

SinteringinchamberfurnacesDebindingandSinteringincombi

furnacesDewaxingFurnaces

Seealsoconceptsfordrying,debinding,thermalcleaningandwaxburnoutincatalogAdvanced

Materials

OvensChamberdryers


Seealsconceptsfordrying,debinding,thermalcleaningandwaxburnoutincatalogAdvanced

MaterialsaswellascatalogThermalProcessTechnologyI

52

Energy Efficiency Concepts

Infaceofrisingenergypricesandstricterenvironmentalregulationsthereisincreasingdemandforheattreatmentplantswithgreaterenergyefficiency.

Dependingonthefurnacesizeandtheprocessthereisalwaysacertainamountofpotentialenergywhichcanberecoveredfromthewasteheatandre-used.Thisisespeciallytrueforlargefurnacesystemsorlongprocesstimeswhichallowforhugeenergysavingsthattheadditionalinvestmenthasashortpay-backtime.Thethermalenergyfromfinishedchargescanalsobeusedtopre-heatcoldchargeswhichisalsoanefficientwayofsavingenergy.

Thefollowingexamplesoutlineengineeringalternativesforheatrecovery:

CounterflowheatexchangerfortheforcedconvectionchamberfurnaceN2560/26ACLS

Recuperatorburnerforaluminummelt-ingfurnace16xTBR110/12and2xTBR180/12

Heattransferbetweenahotandacoldcharge

Productionsystem,consistingoffourchamberfurnacesformovingtheloadduringheattreatmentalongwithathree-stageheatexchangertooptimizeenergyefficiency

Heat Exchangers

Theprincipleofthecounterflowheatexchangeristousethehotexhaustgascomingfromthefurnacetopre-heatthecoldfreshairchannelledintothefurnace.Inmanycases,thereisnoneedanymoreforaseparatefreshairpreheatingunit.Suchasystemisrecommendediftheprocessrequirescontinuousairexchangeinthefurnacechamber,suchaswhentemperingsilicone,orduringdryingprocessesthatarecoveredbytheEN1539industrialstandard.

Recuperator Burners

Largegas-heatedheat-treatmentfurnacesareespeciallyadvantageousfortheinstallationofrecuperatorburners.Recuperatorburnersalsousehotexhaustgas;topre-heatthecombustionair.Dependingonthefurnacemodelandtheprocess,substantialenergysavingsofasmuchas25%canberealizedbyusingrecuperatorburnerssothatthereisashortpay-backtimefortheadditionalpurchasecosts.

Heat Transfer Chambers

Heattransferchambers,whichcanalsobedescribedascooling/heatingchambers,offertwoenormousadvantages.Forone,theyhelpsaveenergy,andforanother,usingaheattransferchamberincreasesproductivity.

Theloadisremovedfromthefurnacewhileitisstillhotandplacedintheheattransferchamber.Thechamberalsohasroomforanew,coldcharge.Circulatingtheaircoolsthehotchargeand,atthesametime,preheatsthecoldchargebeforeitisputintothefurnace.Consequently,thefurnaceheatingdoesnothavetoprovidethethermalenergyandthrough-putcapacityofthefurnaceisincreasedofthesametime.

Theabovesystemsforenhancingenergyefficiencyareonlyafewexamplesoftechnicalalternatives.Wewouldbehappytoadviseyouonwhetheranadditionalheatrecoverymodulewouldalsobeasensibleadd-ontoyourfurnaceorsystem.

53

Spare Parts and Customer Service — Our Service Makes the Difference

Formanyyearsthename Nabertherm hasbeenstandingfortopqualityanddurabilityinfurnacemanufacturing.Tosecurethispositionforthefutureaswell,Naberthermoffersnotonlyafirst-classsparepartsservice,butalsoexcellentcustomerserviceforourcustomers.Benefitfrommorethan70yearsofexperienceinfurnaceconstruction.

Inadditiontoourhighlyqualifiedservicetechniciansonsite,ourservicespecialistsinLilienthalarealsoavailabletoansweryourquestionsaboutyourfurnace.Wetakecareofyourserviceneedstokeepyourfurnacealwaysupandrunning.Inadditiontosparepartsandrepairs,maintenanceandsafetychecksaswellastemperatureuniformitymeasurementsarepartofourserviceportfolio.Ourrangeofservicesalsoincludesthemodernizationofolderfurnacesystemsornewlinings.

The needs of our customers always have highest priority!

· Veryfastsparepartssupply,manystandardsparepartsinstock· Worldwidecustomerserviceonsitewithitsownservicepointsinthelargest

markets· Internationalservicenetworkwithlong-termpartners· Highlyqualifiedcustomerserviceteamforquickandreliablerepairofyour

furnace· Commissioningofcomplexfurnacesystems· Customertraininginfunctionandoperationofthesystem· Temperatureuniformitymeasurements,alsoaccordingtostandardslike

AMS2750F(NADCAP)· Competentserviceteamforfasthelponthephone· SafeteleserviceforsystemswithPLCcontrolsviamodem,ISDNorasecured

VPNline· Preventivemaintenancetoensurethatyourfurnaceisreadyforuse· Modernizationorreliningofolderfurnacesystems

Contact us: [email protected] +49(4298)922-474

[email protected] +49(4298)922-333

Spareparts

Customerservice

+49(4298)922-474

+49(4298)922-333

Pleasevisitourwebsitewww.nabertherm.comandfindoutallyouwanttoknowaboutus-andespeciallyaboutourproducts.

Inadditiontocurrentinformationandexhibitiondates,thereisofcoursethepossibilityofdirectcontactoranauthorizeddealerfromourworldwidedealernetwork.

ProfessionalSolutionsfor:

The whole World of Nabertherm: www.nabertherm.com

· ThermalProcessTechnology

· AdditiveManufacturing

· AdvancedMaterials

· FiberOptics/Glass

· Foundry

· Laboratory

· Dental

· Arts&Crafts

All other Countries: Followhttps://www.nabertherm.com/contacts

ItalyNaberthermItaliaviaTrentoN°1750139Florence,[email protected]

SwitzerlandNaberthermSchweizAGAltgraben31Nord4624Härkingen,[email protected]

BeneluxNaberthermBenelux,[email protected]

Headquarters:

Nabertherm GmbHBahnhofstr.2028865Lilienthal,[email protected]

Sales Organisation

ChinaNaberthermLtd.(Shanghai)No.158,Lane150,PingbeiRoad,MinhangDistrict201109Shanghai,[email protected]

FranceNaberthermSARL20,RueduCapVert21800Quetigny,[email protected]

Great BritainNaberthermLtd.,[email protected]

SpainNaberthermEspañac/MartiiJulià,8Bajos7a

08940CornellàdeLlobregat,[email protected]

USANaberthermInc.64ReadsWayNewCastle,DE19720,[email protected]

RegNo.K5.1/08.21(Englisch),informationhereinissubjecttochangewithoutnotice.Naberthermassumesnoliabilityforanyerrorsthatmayappearinthisdocument.

FURNACES FOR FOUNDRY · 2021. 7. 26. · Tilting furnace K 150/12 Tilting furnace K 150/12 and...

Documents

Transcript of FURNACES FOR FOUNDRY · 2021. 7. 26. · Tilting furnace K 150/12 Tilting furnace K 150/12 and...