The fully automated production sequence starts with laydown of cast logs on the Log Laydown table.

From there logs are moved over an accumulator to the inspection station, where they are visually inspected for surface defects and ultrasonic inspected (Ultrasonic Testing) for center cracks and inclusions.

The Furnace Entry Accumulator provides adequate billet storage between (UT) inspection and continuous homogenizing furnace. For reduced noise and to avoid surface damage logs are lifted and lowered during transfer, no rolling is permitted. Incidentally, this applies throughout the billet production plant.

The log passes through the Continuous Homogenizing Furnace and Cooling Station in fully automated operation.

With extensive, ongoing development substantial improvements have been achieved in recent years:

  • New generation of log supports with special inlays (patented) developed for the log transport system of the furnace. Thereby surface defects on logs can to a large extent be eliminated.
  • Removal of logs from the furnace is by a shuttle car, replacing earlier roller table lines. All rolling and banging of logs has been eliminated.
  • By intensifying hot gas convection and modifying air guide channels, the heat transfer rate onto logs has been increased substantially (without increasing the number of ventilators).
    HE always prefers to rely on a limited number of high-quality powerful ventilators rather than a “forest of ventilators” on top of a furnace.
    The achievement directly results in overheat temperature in the heating zone of max. 5 to 10°K above set homogenizing temperature.
  • Increased production of the furnaces has prompted the desire for increased number of measuring points, even more accurate temperature control and refined data processing.
    Consequently direct temperature measurement has been enhanced  with additional measuring points to achieve higher accuracy.
    The analyses-software with trend analyses, provides an appropriate tool for early recognition of possible changes to the heating regime.
    With its implementation even tighter quality control has become possible.
    Changes of log diameter and homogenizing temperature can be executed with higher safety and great flexibility.
Typical plant layout (40.000 - 150.000 tons/year)
Typical plant layout (40.000 - 150.000 tons/year)
 
Log laydown table
Log laydown table
 
Entry accumulator & Conti-furnace
Entry accumulator & Conti-furnace
 
Conti Plant (150.000 tpy)
Conti Plant (150.000 tpy)
 
Conti Furnace with rapid air cooling station
Conti Furnace with rapid air cooling station
 

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