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new burner (supplied by Bloom Engi-neering) that optimizes heat delivery in the annealing chamber, and minimizes the amount of pollutants that are normally associated with combustion. The design changes also add to the environmental improvements that fol- low the conversion to all hydrogen at

California Style All New All Hydrogen - 21809 CSI,

which operates in the state with perhaps the most restrictive of any emissions regulations. “Integrating Bloom’s air-staging technology for NOx reduction into a cylindrical furnace is a real engineering accomplishment,” boasts Messina. Mechanical and controls factors had to be considered, he points out, “such as minimizing tramp-air infiltration and heating the burner chamber as quickly as possible during a cycle start.” Messina further emphasizes that this and the hydrogen atmosphere will lower CSI’s total utility costs since it makes better use of both electricity and gas. And, he adds, “these are the lowest NOx-producing bell annealing furnaces in the world.”

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Among the more promising ad-vances is a process-management sys- tem designed for CSI by Entec Sys-tems International. Indiana-based Entec designs process control and op-timization systems for heat-treating furnaces, according to its general manager Mike McDonald, and for the past 18 months has been partnered with Rad-Con in a technology sharing agreement.
‘ Usually, we adapt our systems to existing furnaces, sort of an after-market ‘add-on’,” McDonald ex- plains. “Optimization is very much in demand right now.” The CSI project was something of a change. Entec’s proprietary models maxi-mize the effectiveness of gas flows, and heating and cooling phases, as well as monitor coil conditions like cleanliness. Its foundation is an Oracle database accessible through Entec’s Computerized Annealing Process Sys- tem (CAPS) from the operators’ PC. The models recognize coils’ hot and cold spots during annealing and activate or deactivate burners, as needed, to achieve the programmed result most efficiently. “And,” according to Rad-Con’s account manager Mike Luli, “the model is more analytical than empirical, so it adapts very effectively to the circumstances.” According to McDonald, this de-sign—now in operation with the first phase—also demonstrates some new developments. In addition to process optimization, it features an inventory management function. It can determine how to mix and ar-range the coils in a charge, based on information from the plant data network. Thus, coils can be rushed or delayed based on delivery needs; combine or recompose charges based on order fulfillment demands; and mix or separate coils according to compatibility for an annealing cycle. Like all batch annealing operations, furnaces can be run at less than full capacity, but now at higher efficiency. “CAPS manages inventory ahead of annealing,” McDonald indicates, and provides greater control of the information. CSI operators had an earlier-gener-ation Entec modeling package for their former annealing equipment, so adopting the new version was not a great challenge. “The update version is Windows-based, so it’s easier to install changes to the formulas if needed,” Dave Johnson observed. If any help is needed, Entec will be available to perform on-line diagnostics and corrections through an Internet connection. Reprint from 33 MetalProducing, February 2001 (Penton Media, Inc.)