Marcio Boragini Sales Director for Brazil at UPC-Marathon Source: LinkedIn
A gas generator was recently installed for Jomarca, one of the biggest manufacturers of fasteners, bolts, nuts, and fixing elements in Brazil. The generator will supply exothermic gas to a continuous wire annealing furnace, which is part of the manufacturer’s efforts to meet market demand efficiently and sustainably for baling wire in the construction industry.
Using exothermic gas instead of nitrogen, the company expects to reduce operating costs, increase production efficiency, and improve the wear properties and finish of its wire products.
“By providing them with our latest generator technology," commented Marcio Boragini, sales director for Brazil at UPC-Marathon, "we have helped Jomarca improve process efficiency, achieve sustainability, and exceed their customers’ expectations for high-quality wire products.”
Jomarca already owns two endothermic gas generators from UPC-Marathon, a Nitrexcompany with headquarters in North America. In March of this year, the company upgraded its wire operations with a 150 m3/h capacity ExoFlex generator to ensure consistent gas composition and prevent scale formation on the wire surface.
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Daniel Panny Product Manager UPC-Marathon in Germany Source: LinkedIn
OWZ Ostalb received a new electrically heated endothermic gas generator. The company wanted to replace the old generator since it had no automatic process control and was unable to control the dew point efficiency in situations where the ambient air changed too much. The old components, which were difficult to replace, further reduced the generator’s overall efficiency.
OWZ Ostalb, a commercial heat treatment company in Aalen, Germany, received the EndoFlex™ S from UPC-Marathon, a Nitrex business unit, in late 2021.
"The customer chose us," says Daniel Panny, product manager at UPC-Marathon in Germany, "because we offered [a] gas mixing and control system, the EndoInjector™, and the [. . .] ReactionCore™ multi-retort system to deliver a reliable, on-demand supply of quality endogas, resulting in significant CO2 savings for their heat-treating operations."
The EndoFlex™ S that was purchased is the electrically heated version with an air cooler, an automatic nitrogen purge system, and additional CH4 monitoring to meet the highest safety standards.
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Snam, an energy infrastructure operator in Europe, will collaborate with a developer of solutions for the green transition of the metals industry to decarbonize the metals sector in Italy and abroad. The companies will conduct studies and market analysis to implement metal production systems with green hydrogen.
The aim of the collaboration with Tenova is to provide commercial solutions tested in industrial plants to implement reductions in CO2 and NOxemissions. Snam will contribute expertise on hydrogen technologies and transport. Tenova will provide industry knowledge of combustion systems for heat treating.
Cosma Panzacchi EVP for Hydrogen, Snam Photo Credit: Snam.it
“Through this agreement,” Cosma Panzacchi, EVP for Hydrogen at Snam commented, “we further develop our network of partners and projects to introduce green hydrogen into the relevant productive processes of the metals industry. Hydrogen is essential to cut emissions from the production of steel and other metals, as well as from all hard-to-abate sectors such as cement, ceramic, chemistry and refining[. . .].”
“Everyone talks about green hydrogen,” Roberto Pancaldi, CEO of Tenova says, “but the reality is that its supply and use are still limited, and, at the same time, pressures to mitigate climate change are getting stronger. For this reason, we are developing a ready-to-use solution [. . .].”
Ovako, a European manufacturer of engineering steel with a North American presence, will receive a 20MW alkaline water electrolyzer by the end of 2022. The electrolyzer will be used at their plant in Hofors, Sweden for hydrogen heating of steel prior to rolling and hot forming.
Rickard Qvarfort President of Business Ovako Hofors
"In June," says Rickard Qvarfort, president of the business unit at Ovako Hofors, "we announced our collaboration with the Volvo Group, Hitachi Energy, H2 Green Steel and Nel Hydrogen with the purpose to invest in fossil-free hydrogen in Hofors[. . .] We are now very pleased to have reached this important milestone of the project. The electrolyzer technology will enable us to eliminate CO2 for heating steel before rolling."
Jon André Løkke CEO Nel Hydrogen
Nel Hydrogen Electrolyser AS, a division of Nel ASA, is scheduled to deliver the electrolyzer in 2022 for first hydrogen production in 2023. The electrolyzer will produce oxygen and hydrogen for Ovako's steel-heating processes and will decrease CO2 emissions by 50%.
"We are very excited to announce the delivery of electrolyzer equipment to Ovako, and this groundbreaking project," Jon André Løkke, CEO at Nel Hydrogen explains. "There is huge potential in reducing CO2-emissions from steel-heating processes through the use of green hydrogen, there are numerous similar sites with equally large potential for decarbonization across Europe and the rest of the world."
thyssenkrupp Steel Europe (tkSE) has given a parent company of a North American combustion company in Ohio an order to retrofit a FBA 8 combustion system.
Within the scope of a larger modernization project, thyssenkrupp Steel Europe AG (tkSE) will upgrade the combustion system of the FBA 8 galvanizing line, which is located at the Dortmund plant. The newly implemented heating system will provide drastically lower emissions.
The purchase order for delivery, assembly and commissioning of 195 modernized self-recuperative burners has recently been placed with WS Wärmeprozesstechnik GmbH. The heating system will achieve exceptionally low NOx emissions due to proven double P-tube design and the patented FLOX® combustion process. The retrofit is to be completed by mid 2022. Detailed planning will keep line down time to a minimum for the duration of the retrofit.
Dr.-Ing. Joachim G. Wünning President WS Wärmeprozesstechnik GmbH
In the future, the tkSE plant in Dortmund will operate three vertical strip lines, positioning it as an advanced and modern site for annealing and surface treating of steel strip globally. Up to 2.000.00 tons of steel can be processed annually, once all three lines are in full operation. tkSE employs and fully relies on proven and environmentally friendly heating technology. A technology that even today is suitable for a future with green combustion gases. After the conversion, approximately 800 low emissions burners will be in operation at the Dortmund facility.
WS can rely on decades of experience with the FLOX® combustion technology. Experience gained from tens of thousands of burners successfully in operation worldwide. FLOX® enables highly efficient burners to operate while simultaneously maintaining very low NOx emissions. "It is our ambition at WS," states Dr.-Ing. Joachim G. Wünning, president of WS Wärmeprozesstechnik GmbH, "to provide solutions for all continuously operated strip lines which can reliably attain NOx emissions well below 100 mg/Nm³, with simultaneously high combustion efficiency over 80% and which are, already today, suited for a future with green combustion gases."
“In the near term, the thermal processing industry faces landmark decisions and the most commonly postulated future, based entirely on electricity is only one of many possible outcomes. This option, however, is not realistically implementable… there is insufficient green energy surplus to meet expected demand in its entirety.”
Everyone is talking about the future of heat treat and how to process parts for the future. Technology, such as systems related to IoT and 4D, is seen as the solutions. So what about the future of combustion? The color is green.
Read this guest column from WS Thermalwhich summarizes a few key caveats which stand in the way of transforming energy sources. Give it a read, and email editor@heattreattoday.com if you have an op-ed or guest column that you would like to submit to Heat Treat Today!
WS is well known when it comes to low NOx combustion of natural gas in industrial furnaces. By means of the patented FLOX® technology, WS burners can achieve NOx emissions lower than 0.07 #/MMBTU in most operating scenarios, which sets the benchmark for modern gas heated furnaces around the globe. The future, however, belongs to renewable energy sources. Aside from their ecological advantages, it is foreseeable that the economic benefits will become reality far sooner than previously predicted. Even more so, if external effects such as an adequate carbon tax are considered.
In the [short] term, the thermal processing industry faces landmark decisions and the most commonly postulated future, based entirely on electricity is only one of many possible outcomes. This option, however, is not realistically implementable. At this point in time, there is insufficient green energy surplus to meet expected demand in its entirety: heating of thermal process applications, electrolytically generated hydrogen for direct reduction of iron ore, or for fueling long-haul transportation, battery electric mobility, space heating and cooling via heat pumps and many additional applications. Renewable electricity faces demand many times greater than its short or medium-term generation capacity. All this does not even take into consideration the necessity of simultaneous demand and generation in the electric network.
Using a broad spectrum of green energy sources, likely generated in a decentralized manner, and with regional focus on infrastructure capabilities such as transportation and storage of energy carriers, seems more plausible than focusing purely on an electricity-based energy system. However, at this point in time it is impossible to foresee which energy carrier will play the dominant role, or which market shares the various options will garner over time. Hydrogen from electrolysis or from reforming biogas, bio propane, synthetic fuel like ammonia synthesized in sunny regions, or synthetic CH4 which could utilize the existing global transportation infrastructure and current end user devices. The only thing that seems certain is that chemical energy carriers will continue to play a large role in the future. Only they offer the unique advantages such as high availability, high energy density and storage capability, which ultimately enable an airplane to fly, or make it possible to supply thermal processing applications with enough green energy to reliably maintain process temperature for long periods. Therefore, at WS we are committed to our core message: We are …
Regardless of which renewable chemical energy carrier you will ultimately be using in the future, it is already in our focus. Even now, we are implementing technologies aiming at our green future in WS combustion systems. For example, we are exploring technologies that minimize NOx emissions even when combusting ammonia or hydrogen. On a case-by-case basis, we can determine if your WS burners are suitable for use with a given new energy carrier or if a retrofit kit is needed. In any case, due to the long service life of your equipment, what is essential for you to know today is: WS will provide you a state-of-the-art combustion system solution – even if the future comes faster than anticipated.
An industrial gases company recently announced an investment to build a new, large-scale air separation unit (ASU) in Indianapolis, Indiana, a state of the art plant that will produce essential raw materials for metal fabrication facilities and heat treating operations, as well as other manufacturers in the Midwest. The ASU is slated for completion Q1, 2021.
“This investment underscores Messer’s commitment to strategic U.S. expansion to meet growing market demand,” said Jens Luehring, president & CEO, Messer Americas. “We chose to invest in Indianapolis, Indiana, due to its strong pro-business climate and optimal proximity to customers. Messer aims to become the premier supplier of choice for industrial, medical and specialty products in the Americas, providing innovative solutions for our customers with excellent speed to market and reliability. This investment directly supports that mission and strengthens our presence in the Midwest.”
The new air separation plant will produce medical and industrial gases for several industries, including metal fabrication, chemical, welding, glass, healthcare, and food processing.
Mayor Joe Hogsett with the City of Indianapolis
Messer, which acquired most of the North American gases business of Linde plc, as well as certain Linde business activities in South America, is one of the leading industrial gas companies in North and South America.
“We’re excited to keep building a city with a competitive business climate and a vibrant quality of life that appeal to world-class companies like Messer,” said Mayor Joe Hogsett with the City of Indianapolis. “We proudly welcome Messer and the dozens permanent and temporary good-paying jobs that it brings, to the economic landscape of our city.”
A leading U.S. supplier of industrial, medical and specialty gases has recently made moves to increase the company’s bulk gas production and distribution through building and expansion projects and an acquisition of a distributor of industrial gases and welding supplies.
Pascal Vinet, Chief Executive Officer of Airgas, Inc. and Air Liquide Executive Committee Member
Airgas Air Separation Unit
Airgas, an Air Liquide company, announced the plans to build two new air separation units (ASUs) that increase bulk gas production in the Midwest and Northeast. The two new ASUs, along with previously announced production facilities under construction in North Carolina (on-stream late 2019) and Southern California, will produce oxygen, nitrogen, and argon for use in customer applications that include heat treating, metal fabrication, and combustion enhancement.
In addition, Air Liquide announced that Airgas has signed a definitive agreement to acquire TA Corporate Holdings, Inc. (“Tech Air), a large independent distributor of industrial gases and welding supplies. Founded in 1935, Tech Air is a major distributor of industrial, medical and specialty packaged gases, welding equipment, and supplies. Tech Air is owned by CI Capital Partners, a New York-based private equity firm, and Tech Air management.
“With the construction of these two new ASUs, Airgas will deliver on our Air Liquide integration strategy to grow our independent production of bulk gases, to gain efficiencies in our dynamic supply chain, and to deliver product supply reliability to our customers,” said Pascal Vinet, Chief Executive Officer of Airgas, Inc. and Air Liquide Executive Committee Member.
Regarding the Tech Air acquisition, Vinet said, “Growth through acquisition has been a key component of Airgas’ business model and remains a core part of our long term strategy. We look forward to welcoming the Tech Air team to Airgas, and integrating their complementary capabilities and resources to enhance service for our customers.”
The leading U.S. supplier of industrial, medical and specialty gases recently announced plans to build two new air separation units (ASUs), one in the Minneapolis/St Paul area, and the other in Fairless Hills, Pennsylvania.
Pascal Vinet, Chief Executive Officer of Airgas, Inc. and Air Liquide Executive Committee Member
Airgas, an Air Liquide company, projects that the two new ASUs will increase bulk gas production in the Midwest and Northeast and complement Airgas’ strategic independent supply network throughout the United States. The two new ASUs, along with previously announced production facilities under construction in North Carolina (on-stream late 2019) and Southern California (on-stream early 2019), will ensure access to vital supply of atmospheric gases, further enable supply chain efficiencies, bolster network reliability and provide capacity for continued growth.
“With the construction of these two new ASUs, Airgas will deliver on our Air Liquide integration strategy to grow our independent production of bulk gases, to gain efficiencies in our dynamic supply chain, and to deliver product supply reliability to our customers,” said Pascal Vinet, Chief Executive Officer of Airgas, Inc. and Air Liquide Executive Committee Member.
The new ASU near Minneapolis/St. Paul, Minnesota will enhance the company’s gas production to serve growing needs in the Midwest, ensuring long-term reliability of supply and enabling ongoing efficiencies in support of its merchant, packaged and on-site gas customers. Permitting is ongoing and construction will begin in 2019 with operations expected to be on-stream in 2020.
InFairless Hills, Pennsylvania, a new ASU will increase Airgas’ production capabilities throughout the Northeast and Mid-Atlantic regions, particularly to support major bulk gas markets including Philadelphia and New York City. Airgas will build this ASU on a former industrial site to be redeveloped under Pennsylvania’s Land Recycling Program (ACT 2). Construction is underway and the ASU is slated to be on-stream in early 2020.
Each ASU will produce oxygen, nitrogen and argon for use in customer applications such as food chilling and freezing, metal fabrication, blanketing and purging, and combustion enhancement. In addition, the ASUs will produce medical grade oxygen to supply to hospitals, nursing homes and research laboratories as well as food and pharmaceutical grade nitrogen.
A leading industrial gases company recently announced plans to build a new liquid hydrogen plant to produce approximately 30 tons per day at its La Porte, Texas, industrial gas facility to meet increasing product demand from several customer markets, including industries which provide heat treatment.
Global hydrogen provider Air Products will draw hydrogen for the liquid hydrogen plant from Air Products’ existing Gulf Coast hydrogen pipeline system network and is to be onstream in 2021.
“The investment in this new liquid hydrogen production facility in Texas will assist with meeting current customer demand, as well as capture the increased growth that we see coming from several markets,” said Marie Ffolkes, president, Americas at Air Products. “Logistically, our La Porte plant has several operational benefits which make the site selection for this new facility a good choice. We are confident with this additional capacity that we will be able to meet the projected growing liquid hydrogen needs coming from the varied industries in the United States for which a reliable source of this product is vitally important to our customers’ manufacturing operations.”.
Once liquefied at La Porte, the hydrogen will be delivered in trailers to customers in industries which provide heat treatment as well as several others including electronics, chemical and petrochemical, material handling, float glass, edible fats and oils, and utilities.
The new facility at La Porte will join Air Products’ existing hydrogen and syngas production operations, as well as an air separation unit. The liquid hydrogen plant will be connected to, and draw hydrogen from, Air Products’ Gulf Coast Pipeline (GCP), the world’s largest hydrogen plant and pipeline network system. The 600-mile pipeline span stretches from the Houston Ship Channel in Texas to New Orleans, Louisiana, and supplies customers with over 1.4 billion feet of hydrogen per day from 23 hydrogen production facilities.
Photo credit: Air Products. Caption: Air Products employee practices checking a pipeline valve for leaks at the company’s training site in La Porte, Tex.
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