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understanding your demands

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Serving Customers is our Passion

To achieve this -

We take care

We listen to the customer

We provide the best solution

Whether tighter environmental standards, raised production volumes or the quest to cut operating cost challenges our clients, together we fi nd the best way.

We are continuously in the fi eld to guarantee close relationships with our clients and a full understanding of their requirements.

Our clients appreciate our expertise and our accuracy. This is refl ected by a consistently high market share and an increasing number of follow-up orders we are being awarded by all major producers all across the world.

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The History

Since the early 1950s the Manfred Leisenberg KG was well known for its vast experiences in the design and supply of heavy fuel oil burners and fi ring systems for the ceramic and aluminium industry.

At the beginning of the 1990s, Prof. Dr. Leisenberg as a managing director of the company Leisenberg KG recog-nised an increasing demand for the integration of know-how in raw materials and thermal process technologies and process automation into turn-key packages suitable for the customers‘ demands.

In 1991 innovatherm was founded by Prof. Dr. W. Leisen-berg and Hans Lingl Anlagenbau und Verfahrens-technik GmbH &Co. KG, a company established already in 1938 and specialised in the design and installation of turn-key plant in the ceramic and concrete industry.

After having been awarded with prestigious contracts from smelters in the Europe, USA and the Middle East, innovatherm continued in the year 2002 its international expansion by establishing a joint venture company in India.

Representative offi ces in China, Kingdom of Bahrain, South America and the Russian Federation followed.

In 2006 innovatherm started a successful diversifi cation in the aluminium fi eld winning fi rst projects for fume treat-ment centres (FTC) and control systems for Casthouses.

In July 2008 innovatherm USA Inc. started its operation. The company is located in the US State of Missouri and serves the North American Markets.

Starting with world market share of less than 15% innovatherm turned to become the world market leader for fi ring and process control systems for anode baking furnaces, operating over 130 fi res on more than 50 different anode baking furnaces worldwide.

Since 1999 innovatherm is certifi ed according to DIN EN ISO 9001:2008 quality standards.

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Excellence is our Attitude

innovatherm accepts the challenge to develop outstanding solutions and technologies.

Premium products and proven technologies are the results to ensure best performance.

innovatherm is driving the thermal process industry for more than 40 years. Specialized in the ceramic and aluminium industry, we offer comprehensive solutions to control the production in the most effi cient and effective manner.

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Product Range

ProBakeAdvanced fi ring systems for baking furnaces

The ProBake advanced fi ring and control system is de-signed to ensure a safe and reliable baking process. The control strategy is based on the implementation of intelli-gent control modules on top of the basic automation for an optimum production at lowest energy consumption and emissions, which sets bench marks in the industry.

ProCleanIntegrated fume treatment technology

ProClean includes a sequence of processing stages which are combined in a way to guarantee a maximum treatment and cleaning of waste gases produced in the baking process – and with continuous feedback to the ProBake fi ring system.

ProCastCharging and Melting management system for casthouses

The charging and melting management system Pro-Cast optimises the production in primary or secondary casthouses. It is based on fuzzy logics and advanced generic algorithms providing functions for an improved charging and melting procedure at lowest raw material costs and best economics.

ProCeramFor the ceramic industry

ProCeram includes a family of products designed for the ceramic industry.

novacontrol is a process control system designed for the special demands of the ceramic industry. The design supports all functions for operating kilns, dryers and auxiliary equipment most effi ciently.

The novatronic moisture and plasticity control system is the worldwide leading technology with more than 1.000 installations in operation.

novapuls includes special equipment like burners and magnetic valves which have been developed for fuel gas and oil for the ceramic industry.

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The ProBake fi ring and control system is tailored to suit customer’s requirements utmost. Innovatherm’s control philosophy is based on the implementation of intelligent optimization modules on top of the basic automation using State-of-the-Art and future oriented technologies.

ProBakeFiring Systems for baking furnaces

Inspired for best per formance

The innovatherm integrated Baking Furnace Firing and Control System ProBake combines 40-years of experi-ence in open top and closed type baking furnaces with the latest fi ring and control technology. ProBake offers an optimum approach to an effi cient and economic operation of

open or closed type

existing or new furnace design

fuel oil or natural gas fi red

high productivity type

carbon baking furnaces.

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The ProBake System features

Robust and sturdy ramp design, proven technology

User friendly, simple operation from local manual to central automatic

Preheat Control with complete internal pitch burn

Firing Control with maximum fuel effi ciency

Cooling Regime with zero point control

Automatic Cross Over strategy optimized including pre- and post corner situations

Combustion safety circuits complying to latest safety regulations

ULTRA LOW NOx pulse burner technology to ensure effi cient combustion and temperature distribution

Preparation of the equipment for reversal of fi re direction

Full Combustion Management by Advanced Control Modules

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Advanced Technologies

The ProBake System is enhanced by advanced tech-nologies for a most effi cient and economic production process. This will maximize the productivity of the furnace ensuring faster fi re cycle times at high baking quality and lowest energy consumption.

These technologies include:

Pitch burn module for maximum pitch volatile combustion, driven by Opacity and/or CO control

Flow Control Module, Flow Prediction for each fl ue by Fuzzy Logics

Total Firing Flexibility by section oriented baking curves

WiFi Technology (Wireless) for high reliability and low maintenance

Low NOx Burner Technology for lowest emissions

innovatherm short pulse dosing valve, heavy-duty design, lifetime 500.000.000 operation cycles

RFID Technology for Automatic Position Detection

Long Life Flue Thermocouple Type S with patented shock absorber technology, Pat. US 8,690,565

ProDat data management and historical archive for all baking data

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Proven Performance and Flexibility

The ProBake System is designed to achieve

The lowest energy consumption

A total pitch burn

Lowest emissions

Highest consistent anode quality

The System provides full fl exibility to adapt

Variations in raw materials

Increase in anode weight

Variations in pitch content

Changes in baking temperatures

Furnace ageing

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ProClean Fume Treatment Technology

Thinking the entire chain

The ProClean Fume Treatment Technology is focused on a sophisticated interlocking of all processing stages from Combustion to Waste Gas Cleaning.

The combination of optimized fi ring technologies, including total pitch burn, with perfectly matched fi lter technology minimizes the emission levels and maximizes both plant reliability and cost effi ciency.

The ProClean plant is of modular design and complies with any future changes in laws, regulations and directives.

ProClean includes a sequence of processing stages which are combined in a way that a maximum treatment and cleaning of waste gases generated in the combustion process is guaranteed.

The technology used for the adsorbtion of HF, SO2 and other particles is designed as a triple stage process as follows:

fl ue gas cooling and conditioning

fl ue gas enrichment with adsorbant in a reactor and a multiple recirculation strategy

fi ltration, centred in a fabric fi lter.

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Sophisticated Control

Feed-back and feed-forward control strategies between the fi ring control and the fume treatment control are used to achieve a minimum emission level with optimisation of the throughput capacity.

Move procedures, pitch burn activities are integrated into the overall control strategy to adjust the amount of water, alumina, pressure and fl ow rate dynamically.

innovatherm’s fume treatment technology stands for

maximum operational fl exibility,

minimum usage of adsorbent,

highest reliability of the plant

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ProCastCharging and Melting

Management System

innovatherm provides the ProCast Charging and Melting Management System to optimize the production in primary or secondary Casthouses. It is based on fuzzy logics and advanced generic algorithms providing func-tions for an optimized charging and melting procedure at lowest raw material costs and best economics.

The following functions are available:

Charging Management

The charging management is integrated into a complete solution starting at charge assignment, including charge calculation and charge tracking, and providing

Scrap and raw material identifi cation at Scrap Yard

Charge planning for each batch and each furnace

Automatic Target Alloy Calculation and Optimisation of Batch Costs

Supervision of Metal Analysis

Weight Balancing for each Furnace

Material Tracking through the Casthouse

Quality Control according to ISO 9001

Production Documentation

Melting Management

The melting management optimizes the temperature re-gime for each furnace and supervises the corresponding melting cycles. It provides functions for

Adaptation of Temperature Setpoints for Exhaust, Roof and Bath

Supervision of Oxygen level Survey of Stirring Procedures Survey of Skimming Procedures Survey of Pyrolyse, Melting cycle time “Ready for Cast” Signalisation (just-in-time)

Benefi ts

The implementation of ProCast results in numerous im-provements at Casthouse production level, as there are

Improvement of product quality and reliability Improvement of raw material cost situation Minimization of melting cycle times Minimization of dross formation (metal loss) Minimization of fuel consumption Minimization of emissions

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ProCeramUnderstanding the process as a whole

Pro Ceram includes a family of products designed for the ceramic industry as there are novacontrol, novatronic and novapuls.

We consider all steps from raw materials characteristics, their preparation, the extrusion and drying up to the fi ring and take care of all single phases of the production pro-cess and their dependencies.

Novacontrol

The Novacontrol process control system is designed for the special demands of the ceramic industry. The design supports all functions for operating kilns and dryers most effi ciently.

Novacontrol provides

easy handling for the operators

fully automatic control of the process

maximum support and diagnostics for the operator

high fl exibility in adaptation to customer’s demands

highest reliability

A confi gurable control structure, powered by a graphical editor is integrated into the system to design an advanced and sophisticated control strategy for optimisation and adaptation of the process.

The focus is put on

the mass fl ows of the raw materials and the dosing water

the production performance of the dryer and the kiln

the product quality

the energy consumption and the energy effi ciency

Novatronic

The Novatronic moisture and plasticity control system is the worldwide leading technology with more than 1.000 installations in operation. It guarantees a constant and reproducible clay plasticity.

The Novatronic system consists of

plasticity sensors and dosing units for water and steam using different technologies

stand alone control unit, based on S7 technology and touch screen

Novapuls

The Novapuls product line comprises pulse- fi ring components for fuel gas and oil.

Novapuls impulse oil burner

heavy or light fuel oil

high pulse frequency

low wear, robust design

purge air connection

vy or light fuel oil

pulse frequency

weaear,rr, r robo ust design

ge air conneectctctioionn

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Novapuls start-up burner

gas or light fuel oil

atmospheric burner with air injection

for start-up of furnaces up to self ignition temperature (750°C)

large capacity range

optional with fl ame supervision (ionisation or UV cell)

Novapuls impulse dosing valve

for gas or light fuel oil

approved as a safety valve class A for all combustible gases up to 3,0 bar

EC type approval acc. to EN 161 and compliant as a safety shut off valve according to EN 746/2

long lifetime (500,000,000 switch cycles)

Headquarter

innovatherm GmbH+Co. KGAm Hetgesborn 2035510 ButzbachGermany

Tel.: +49 6033 9696 0Fax: +49 6033 9696 9e-mail: offi ce@innovatherm.deinternet: www.innovatherm.de

innovatherm USA Inc.3496 State Highway 80Matthews, MO. 63867USA

Phone: +1 573 380 70 54

e-mail: dwilburn@innovathermusa.cominternet: www.innovatherm.com

USA Inc.

innovatherm.com

Worldwide at your service

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