Spectra Aluminum signed the Final Acceptance Certificate for the equipment installed have Danieli Breda, consisting of a 28-MN, front-loading direct extrusion press and an Eco-flame high-efficiency gas billet-heating furnace. The new line expands the company's operation in Bradlord, Ontario, Canada, and will be dedicated to producing architectural, industrial and automotive profiles, starting with 8-to-9" aluminum billets. For the equipment design, special attention was dedicated to energy efficiency. In fact, the extrusion press is equipped with Danieli's patented ESED 4.0 Energy-saving solution, which allows considerable energy savings compared to traditional systems available on the market.Upstream the press, Danieli Breda's Eco-flame gas billet-heating furnace will deliver up to 5,000 kg/h of billets to the press at 480 degree Celsius, with minimum gas consumption. Such a result would not have been possible without extensive research and development of multiple furnace components. First of all, to improve flame efficiency and heat transfer to the billet, particular care was dedicated to the burner design, which takes different shapes according to the furnace /one where they are deployed—and their manufacturing, with benefits coming from the adoption of advanced technologies, such as 3D printing. Ultra-high heating rate burners, UHHR for short, are used in the taper zone, where an accurate tern-5,000 kg/h billets delivered from Eco-flame furnace to the pressOn the other hand, distributed healing rate burners, DHHR, are dedicated to the intermediate zone, where heat exchange is maximum: the 3D printed diffuser allows the generation of a swirl movement which, combined with the burner's large diameter, maximizes heat transfer with no risk of local billet melting. Finally, high heating rate burners, or HUR, make sure heat is efficiently exchanged even under high temperature differences, a characteristic environment for the first zones of the furnace.Combustion is then efficiently controlled by means of multivariable transmitters, which continuously measure temperature and pressure of both air and gas and use these data to regulate the gas and air mixture in closed-loop control. This makes it possible to work in optimal conditions at all times, reducing the need for maintenance and manual adjustments.Furthermore, several heat exchange areas are foreseen, fully utilizing the fuel thermal energy, starting from direct combustion energy up to the preheating ol combustion air and aluminum logs by means of low-temperature fumes.Finally, thermal insulation has been improved: heat losses are minimized, and the external surface temperature never exceeds 30 degree Celsius above room temperature. Field results were outstanding, showing a net natural gas consumption in the range of 14 Nm3/t, depending on final billet temperature. After heating, billets are transferred to the extrusion press by the press loader itself, which directly links the furnace to the press.
Spectra Aluminum signed the Final Acceptance Certificate for the equipment installed have Danieli Breda, consisting of a 28-MN, front-loading direct extrusion press and an Eco-flame high-efficiency gas billet-heating furnace. The new line expands the company's operation in Bradlord, Ontario, Canada, and will be dedicated to producing architectural, industrial and automotive profiles, starting with 8-to-9" aluminum billets. For the equipment design, special attention was dedicated to energy efficiency. In fact, the extrusion press is equipped with Danieli's patented ESED 4.0 Energy-saving solution, which allows considerable energy savings compared to traditional systems available on the market.Upstream the press, Danieli Breda's Eco-flame gas billet-heating furnace will deliver up to 5,000 kg/h of billets to the press at 480 degree Celsius, with minimum gas consumption. Such a result would not have been possible without extensive research and development of multiple furnace components. First of all, to improve flame efficiency and heat transfer to the billet, particular care was dedicated to the burner design, which takes different shapes according to the furnace /one where they are deployed—and their manufacturing, with benefits coming from the adoption of advanced technologies, such as 3D printing. Ultra-high heating rate burners, UHHR for short, are used in the taper zone, where an accurate tern-5,000 kg/h billets delivered from Eco-flame furnace to the pressOn the other hand, distributed healing rate burners, DHHR, are dedicated to the intermediate zone, where heat exchange is maximum: the 3D printed diffuser allows the generation of a swirl movement which, combined with the burner's large diameter, maximizes heat transfer with no risk of local billet melting. Finally, high heating rate burners, or HUR, make sure heat is efficiently exchanged even under high temperature differences, a characteristic environment for the first zones of the furnace.Combustion is then efficiently controlled by means of multivariable transmitters, which continuously measure temperature and pressure of both air and gas and use these data to regulate the gas and air mixture in closed-loop control. This makes it possible to work in optimal conditions at all times, reducing the need for maintenance and manual adjustments.Furthermore, several heat exchange areas are foreseen, fully utilizing the fuel thermal energy, starting from direct combustion energy up to the preheating ol combustion air and aluminum logs by means of low-temperature fumes.Finally, thermal insulation has been improved: heat losses are minimized, and the external surface temperature never exceeds 30 degree Celsius above room temperature. Field results were outstanding, showing a net natural gas consumption in the range of 14 Nm3/t, depending on final billet temperature. After heating, billets are transferred to the extrusion press by the press loader itself, which directly links the furnace to the press.
