Clam Type Pre-Forging Heat Treatment Furnaces

Client

Leading UK alloy and metal components manufacturer

Services / Products

Design, supply, installation and commissioning of two Clam type heat treatment furnaces PLC System.

Scope of Service

This contract, for a client in Sheffield, required two high efficiency furnaces capable of close tolerance heat treatment of ESR ingots prior to forging in a forging machine.

The load in each furnace was up to 45 tonnes of aerospace materials requiring tight tolerance to temperature control ramp and final soaking to ±5°C between 450 to 750°C and ±10°C up to 1190°C. This aim was to provide improvements in production flow in addition to improved consistency of heat treatment and energy savings.

The furnaces were fitted with latest pulse fired ultra-low NOx Natural Gas burners with waste heat recovery to minimise energy consumption.

A low level individual recuperator supplied each burner, positioned at high level, with pre-heated air and each burner was fitted with an exhaust gas recirculation supply. The burners were mounted in staggered opposed orientation.

The controls were operated from a remote operator pulpit and included a PLC to manage combustion and burner pulsing in response to command from operators and process controls, HMI operator interface and chart recorders.

The furnace lid, Clam, was required to open through a full 90 degrees to facilitate crane access for loading and unloading and was lined with non-carcinogenic ceramic fibres. The hearth was a composite of insulation and hard-wearing working layer refractory concrete.

Benefits of our work

• Plant commissioned to meet client’s schedule
• All objectives for close tolerance control met (RPS 953 and AMS 2750 requirements)