1、COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling ServicesTable of Contents Processinq “Modern Pusher-Type Furnaces for Reheating and Homogenizing Aluminum Ingots at Alcan Osweg
2、o, NY and Logan Russellville, KY” . 1 Karl Gdovka, Alcan Rolled Products company Gerhard Richter, Ebner-lndustrieofenbau Ges.m.b.H. B.Ren, University of Kentucky J.G. Morris, University of Kentucky W.Y. Lu, University of Kentucky “Ultrasonic Determination of Texture in AA 31 04 Sheet Materials” 23 “
3、A New Technology for the Cooling and Quenching of Hot-Rolled Aluminium Plates” . 41 Malcolm Hill, Alusuisse Aluminium Suisse S.A Miroslaw Plata, Alusuisse-Lonza Services Ltd. Ren Von Kaenel, Alusuisse-Lonza Services Ltd. Rolling “Model Supported Profile and Flatness Control Systems” 57 Achim Schneid
4、er, Mannesmann Demag Corp. Paul Kern, Mannesmann Demag Corp. Martin Steffens, Mannesmann Demag Corp. Wolfgang Rohde, SMS Hans Georg Hartung, SMS Peter Sudau, SMS Gerard Collette, Pechiney-Rhenaulu Neuf-Brisach Patrick Malewicz, Pechiney-Rhenaulu Neuf-Brisach Jean-Philippe Guillerault, Pechiney-Vorep
5、pe Research Center Michel Morel, Davy-Clecim G.D. Holmesmith, Kaiser Aluminum & Chemical Corporation, Trentwood Works E.A. Leclerc, Kaiser Aluminum & Chemical Corporation, Trentwood Works C.A. Moyer, Kaiser Aluminum & Chemical Corporation, Trentwood Works K.K. Sundar, Kaiser Aluminum & Chemical Corp
6、oration, Pleasanton “Recent Developments in Aluminum Hot and Cold Rolling” . 71 “The Practical Applications of the Dynamic Shaperoll” . 11 1 “Enhancing Rolling Mill Control Systems to Increase Recovery” 147 Rolling Mill Technology” 161 A.Barten, Achenbach Buschhtten Dr. M. Falk, Achenbach Buschhtten
7、 F. Sommer, Achenbach Buschhtten COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services“Closed Loop Profile Control of an Aluminum Hot Mill” . 195 R.J. Beattie, Davy Interna
8、tional P.F. Round, Davy International A. Storey, Davy International Stephen J. Outhwaite, Data Measurement Corporation “Methods of Measuring Aluminum and its Alloys Using Radiation” 21 9 “Eddy Current Temperature Measurement During Hot Rolling of Aluminum Sheet” 247 L.C. Phillips, National Institute
9、 of Standards and Technology A.H. Kahn, National Institute of Standards and Technology Allen B. Cain, Nichols Aluminum Anders G. Carlstedt, ABB Industrial Systems Inc. Mark A. Schueler, ABB Industrial Systems Inc. “Strip Flatness Improvements at Nichols Aluminum 261 “ABB-AccuRay Advances in Thicknes
10、s Measurement using Beta Measurement” 273 Mike Ramsey, ABB Industrial Systems, Inc. Surface Inspection “Web Scanning Experiences in Aluminum Products” .275 “Temperature Control of an Aluminum Warm Mill” . 287 Leon R. Zoeller, Veredus Products Division of Ektron R.J. Beattie, Davy International P.F.
11、Round, Davy International A. Storey, Davy International Ren Nussbaum, Lauener Engineering AG Andy Ewald, Lauener Engineering AG “VISTA Surface Inspection System” . 309 “The is-2000 Automated Surface Inspection System and How Reynolds Metals Company is Using it to Improve Canstock Production . 31 9 J
12、ohn Badger, Isys Controls Inc. Mark Wilson, Reynolds Metals Company, Alloys Plant, Muscle Shoals, AL Finis hinq “Total Gauge Deviation Prediction Model” 327 Jeff rey Kadilak, Alcan Rolled Products Co. COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGH
13、T The Aluminum Association, Incorporated Licensed by Information Handling Services“Design, Installation, and Start-up of 5,000 FPM Rigid Container Sheet Slitter at Logan Aluminum” . 363 Robert L. Clune, Monarch/Stamco Karl Gdovka, Alcan Rolled Products Company Castinq “The Aluminum Mini Mill” 385 “E
14、limination of Surface Streaking on Finished Sheet Cast on Hazalett Casters” . .407 Thomas Diener, Davy International Renata Szczypiorski, Hazelett Strip-Casting Corporation Wojtek Szczypiorski, Hazelett Strip-Casting Corporation “High Speed Thin Strip Casting Comes of Age” . 423 P.M. Thomas, Davy In
15、ternational P.G. Grocock, Davy International “Waste Reduction In Aluminum Foundries” 451 “Current Developments in Burner Design to Reduce NO, Emissions . 469 Dieter Leidel, Tanoak Enterprises, lnc. Glenn Baggiey, Bloom Engineering Company, Inc. Charles Lied, Bloom Engineering Company, Inc. Stewart J
16、epson, Air Liquide America Corporation “Oxygen Combustion for Aluminum Melting Furnaces” 477 “The Dynamics of Improved Circulation and Gas Injection Pumping Technology” 487 R.S. Henderson, Metaullics Systems Co. L.P. R.E. Gilbert, Metaullics Systems Co. L.P. D.M. Masarin, Metaullics Systems Co. L.P.
17、 G.S. Mordue, Metaullics Systems Co. L.P. C.T. Vild, Metaullics Systems Co. L.P. James Bailey, SECOMlatwick “Modernizing for Todays Markets” . 507 “Parametric Study, Using Numberical Simulation for Caster Shell Optimisation and New Developments” . 51 3 M. Laugier, C. France, IRSID J. Terrasse, Forca
18、st G. Vidalenc, Forcast COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services“Thin-Gauge / High-speed Roll Casting Technology for Foil Product ion” . 545 Bruno Taraglio, Fa
19、ta Hunter Engineering Chris Romanowski, Hunter Engineering “Cartridge Filter Technology for Strip and Foil” . 563 “The Benefits of Measurement and Control for Aluminum Rolling Mills” . 581 “SCR-Special Crown Roll and Automatic Flatness Control with SCR . 593 Dr. David Neff , Mataullics Systems Co. L
20、.P. Craig Wolf, Measurex Corporation D. Greven, Mannesmann Demag Sack GmbH U. Rttinger, Mannesmann Demag Sack GmbH P. Huck, Mannesmann Demag Sack GmbH COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed
21、by Information Handling ServicesModern Pusher-Type Furnaces for Reheating and Homogenizing Aluminum Ingots at ALCAN Oswego, NY and LOGAN Russellville, KY 1 EBNEFUALCAN Paper: Ric,GdovkalAlumitech94 USAI1 0.94/am EBNER Industrieofenbau COPYRIGHT The Aluminum Association, Incorporated Licensed by Info
22、rmation Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services3 I Modern Pusher-Type Furnaces for Reheating and Homogenizing Aluminum Ingots at ALCAN Oswego, NY and LOGAN Russellville, KY Authors: Karl A. Gdovka, P.E. Director, Process Reliabilit
23、y & Engineering, ALCAN Rolled Products Company, Cleveland/OH Gerhard E. Richter, Ing. Project Manager, EBNER-lndustrieofenbau Ges. rn. b. H., Li nz/Au st ri a Text translated from German by Ludwig Kahne. 1. INTRODUCTION Pusher-type furnaces are semi-continuous reheating/homogenizing furnaces. Unlike
24、 traditional furnaces where heating/cooling is done on a batch basis, with the pusher-type furnaces, each ingot has its own cycle and loading/ unloading of the furnace is done on a semi-continuous basis. That is, for each unloaded (extracted) ingot, one new ingot is loaded (pushed-in). The ingots ar
25、e subjected to the reheating or homogenizing cycle as they move through the various heating zones of the furnace. At the end of the cycle the ingot is at the unloading end (exit side) of the furnace, ready to be rolled. This paper describes the design features, installation and production results of
26、 the three pusher-type furnaces installed for ALCAN Rolled Products Company. The project was initiated in 1989 when ALCAN awarded the contract to EBNER for design, fabrication, installation and commissioning of two pusher-type furnaces for LOGAN Aluminum, Inc. in Russellville, KY and one for ALCANs
27、Oswego Works in Oswego, NY. The furnaces were custom-designed to take into account the process needs and layout of each facility. These furnaces are the largest modern pusher-type furnaces in operation in the world. Each furnace has the capacity to process 31 full size ingots at any one time in a se
28、mi-continuous mode. EBNEWALCAN Paper, Ric.GdovkdAlurnW94 USAnO.Warn 1 GUoB87.VTA COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services4 Considerable effort and emphasis was
29、 given to the scoping and planning of the project to ensure that both the customers needs were met and that the supplier had the technical capability to meet these needs. EBNER, as renomated furnace manufacturer was the best possible choice for ALCAN. EBNER could not only fall back on many years of
30、experience in offering the most modern furnace technology, but could also make good use of its well equipped R 81 D laboratory at the main factory in Linz/Austria, to carry out full-scale tests in order to optimize the design of the furnace. In the course of such a test, a recirculation fan and the
31、jet nozzle air flow system (both components of considerable importance in a pusher-type furnace) were tested and optimized during the early stages of fabrication of the first furnace (see fig. 1) fig. 1: full scale test at EBNER LinzlAustria All three furnaces were successfully installed and are pre
32、sently in operation in both ALCAN locations and the performance to date has been excellent. The success of the project was in part due to the up-front, well scoped and planned work done by both the vendor and buyer personnel working as a team. 2 GUW1887.VTA COPYRIGHT The Aluminum Association, Incorp
33、orated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services5 2. BASIC DESIGN REQUIREMENTS All three furnaces were built to the same technical specifications. Some of the typical technical/processing requirements are show
34、n below. a) material: mate rial : max. ingot dimensions: - length - Width - thickness max. ingot weight: b) pusher-type furnace: max. furnace temperature: number of ingots: max. weight of charge: number of heating zones: type of heating system: number of burners: max. burner rating: max. heat input:
35、 number of recirculation fans: aluminum alloys 302“ (7671 mm) 84“ (2134 mm) 29“ (737 mm) 68 O00 Ibs (30 845 kg) 1256F (680C) 31 992 US tons (900 metric tons) 8 direct gas fired 58 1 584 O00 BTU/h (400 O00 kcal/h) 91 872 O00 BTWh (23 200 O00 kcal/h) 16 fan motor size: 160/43 HP (1 20/32 kW) 3 GU887.V
36、TA COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services6 3. LAYOUT OF THE PUSHER-TYPE FURNACE FACILITIES Although the furnaces were built to the same basic specifications,
37、 the layout and installation in each plant was different. The reasons for this were to accommodate the space constraint and material flow pertinent to each location. For example, each furnace installed at LOGAN Aluminum is equipped with an individual (furnace-related) ingot handling & shoe return sy
38、stem, whereas the furnace installed at ALCANs Oswego Works is designed with a shared ingot handling & shoe return system to serve future furnaces. a) layout - LOGAN Russellville, KY: The overall layout is designed for a total of three pusher-type furnaces, each with its individual (furnace-related)
39、ingot handling & shoe return system (see fig. 2). At the entry of the furnaces single ingots or ingot stacks are transported from the scalper to the furnace by means of an automatic guided vehicle (AGV) where they are then placed onto a lay-down table. Each of the two furnaces is equipped with an au
40、tomatic gantry crane which transfers the ingots from the lay-down table to stacks in front of the furnace. In this way a complete charge of 31 ingots can be stored in front of each furnace. The same gantry crane then picks the stored ingots in sequence and places them on the upender which raises the
41、 ingots to a vertical position for pushing into the furnace (entry side ingot handling equipment see fig. 3). At the exit end, each furnace is equipped with a downender which tilts the hot ingots extracted from the furnace from vertical to horizontal position and places them centrally on the hot mil
42、l roller table (exit side ingot handling equipment see fig. 4). EBNERIALCAN Fapar. Ric.GdovkdAiumitech94 USAnO.S4/am LI 4 GUoo1B87.VIA COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information H
43、andling Servicesfig. 2: layout - LOGAN Russellville, KY fig. 3: entry side - LOGAN Russellville, KY BNEWALCAN Paper. Ric.GdovkalAlumitechS4 USAHO.Warn 5 GUW1887.VTA 7 COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorp
44、orated Licensed by Information Handling Services8 fig. 4: exit end - LOGAN Rucsellville, KY The shoe return system at LOGAN transfers the empty shoes underneath the furnace back to the entry side. b) layout - ALCAN Oswego, NY: The overall layout is designed for two additional pusher-type furnaces. T
45、he shared ingot handling & shoe return system can serve all three furnaces (see fig. 5). At the furnace entry, the scalped ingots are transported from the storage area to the charging roller table by means of an overhead crane. This charging roller table includes a centering mechanism and a weighbri
46、dge. From the charging roller table, which is long enough that a total of 5 ingots can be stored on the various roller table sections, the ingots are transferred onto the upender. The upender raises the ingots from their horizontal to a vertical position and the cross travel car then moves the ingot
47、s sideways to the furnace entry (entry side ingot handling equipment see fig. 6). EBNWALCAN Paper. Ric,Gdovka/AlumMW UW1O.Wam 6 GW1887.VTA COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Informati
48、on Handling Servicesfig.5: layout - ALCAN Oswego, NY fig.6: entry side - ALCAN Oswego, NY 7 9 COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services COPYRIGHT The Aluminum Association, Incorporated Licensed by Information Handling Services10 At the exit end, the h
49、ot ingots, after being extracted from the furnace, are drawn onto the exit end cross travel car which moves the ingots sideways to the downender. The downender then lowers the hot ingots to a horizontal position and places them centrally on a lay-down roller table which is an extension of the hot mill roller table (exit side ingot handling equipment see fig. 7). fig. 7: exit end - ALCAN Oswego, NY At ALCAN Oswego, NY, only the pusher and extractor mechanisms are dedicated to the furnace. All other items are part of the shared ingot handling equipment. This is also tru
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