Insertec » Thermal Engineering Solutions » Projects

Project description

The main objective was to thermally process around 300,000 automotive parts/year, LPDC aluminium structural subframes, by means of a continuous “tailor-made” T6 heat treatment installation in a “closed loop” arrangement. Insertec plant engineering was deeply involved in the project from the beginning, we had severe limitations of available floor space.

The installation includes the following equipment:

  • “Hybrid-type” solution annealing Furnace.
  • Water quenching station.
  • Intermediate straightening area.
  • Transfer table connecting both process lines.
  • Electrical artificial aging Furnace.
  • Forced air cooling chamber.
  • Loading&unloading stations.

Benefits

  • Reduction of generated carbon footprint of production activity by the use of “hybrid” (gas-fired burners + electric resistances) and electrical heating systems, comparing with totally gas-fired ones.
  • Reduction of greenhouse effect gas emissions to atmosphere.
  • Complete process traceability of heat-treated parts.
  • Product quality assurance by CQI-9 certification.
  • Minimize handling operations of load baskets on site due to “closed-loop” workflow, extending respective service life (OPEX saving).

Project description

Customer´s main objective was processing 100.000 ton/year of post-consumer scrap with the maximum metal yield, to reduce the primary aluminum remelting, obtaining Low Carbon Footprint aluminum products.

Insertec metallurgy engineers were involved in the project from the beginning, studying the best way to process three available different scraps (UBC, extrusion & chips).

The solution provided was based on IDEX® rotary delaquering unit and Aluswirler® vortex immersion melting system. This project was replicated later in customer´s three different facilities.

Benefits

  • Metal yield improvement.
  • Minimum dross generation, comparing with other post-consume processing technologies.
  • Overall plant competitiveness increase.
  • Low Carbon Footprint semi-finished goods production.

Project description

The client sought to increase their low carbon aluminum billet production capacity with a next generation recycling technology that offered energy efficiency, environmental sustainability and productivity. Additionally, a minimization of downtime through a robust design and accessible maintenance features and a quick installation and commissioning process were required.

To address these challenges, Insertec engineering team brings the best available technology: the CDM Eco-Unit® System, a state-of-the-art combined decoating and melting process system. Key features include:

  • Customized Design
  • Process monitoring
  • Metal Recovery
  • Improved Energy Efficiency
  • Intelligent Automation and Control

Benefits

The installation of a new CDM EcoUnit® system had an immediate and positive impact on Hydro’s operations. Key results include:

  • Energy Savings: reduction in energy consumption, exceeding the client’s initial target.
  • Productivity Increase: increase of molten aluminum production from post-consumer scrap, with the highest metal recovery.
  • Emission Reduction: Full compliance with local environmental regulations
  • Client Satisfaction: Hydro praised the swift and professional installation as well as the furnace’s reliability in continuous operation.