Three aluminum melting furnaces at a Novelis site have been updated to achieve a more than 40% reduction in carbon footprint and significantly lower gas consumption. This project marks an important step forward in the decarbonization of industrial processes.
The upgrade includes Fives’ North American® regenerative technology. The North American TwinBed® II burners, manufactured by the supplier, are recognized for their energy efficiency and low emissions. From engineering and design to commissioning, the project was fully managed by Fives’ North American Combustion’s teams based in Bilbao, Spain.
Aluminum melting furnaces updated for environmental impact (Source: Novelis)Novelis and Fives upgrade three furnaces (Source: Novelis)Emilio Braghi, Executive Vice President and President Novelis Europe
Source: Novelis
This joint initiative in Voerde, Germany, by Novelis and Fives highlights the shared commitment to sustainability and innovation. The 40% reduction in carbon footprint is based on gas consumption compared to pre-upgrade levels measured in mid-2023 at the Voerde casthouse.
“Sustainability is at the core of Novelis’ business model,” said Emilio Braghi, executive vice president and president of Novelis Europe. “With our company vision, Novelis 3×30, we’ve set ambitious goals to advance circularity and decarbonization by 2030. The upgrade of our three melting furnaces represents a practical advancement in reducing our environmental footprint and improving operational efficiency.”
“This project represents a new milestone in our long-standing collaboration with Novelis, which began nearly two decades ago,” added Pablo Arribalzaga, managing director for Europe at Fives North American Combustion. “We are proud to support Novelis’ sustainability journey with high-performance, low-emission combustion solutions tailored to their operations.”
Press release is available in its original form here.
Relevant Industrial, LLC (Relevant), an industrial equipment and engineered solutions company, has announced its acquisition of Lindberg Process Equipment (Lindberg), a provider of industrial heating and combustion systems. The acquisition adds to Relevant’s geographic presence in the Midwest while expanding its ability to support its clients.
John Carte CEO Relevant Source: Relevant Industrial, LLC
Lindberg’s operations will combine with Relevant’s New Brighton, MN location, adding an established thermal solutions operation. The move allows the company to provide faster response times, improved product availability, and more tailored support to industrial clients across the Midwest.
“This acquisition reinforces our commitment to being close to our customers and equipping them with the products and solutions they need to keep their operations running efficiently,” said John Carte, CEO of Relevant Industrial. “By expanding our thermal solutions capabilities in a key geography, we’re better positioned to deliver timely, practical support.”
Lindberg Process Equipment specializes in industrial heating and combustion systems, including burners, valves, pipe trains, controls, and custom control panels.
Press release is available in its original form here.
Heat treatment is a hands-on science and it can be easy to forget about continuing education. In today’s edition of Combustion Corner, Jim Roberts, president of U.S. Ignition, encourages readers to continue cultivating their own heat treat learning and offers specific and practical educational resources to do just that.
This informative piece was first released in Heat TreatToday’sJune 2025 Buyers Guide print edition.
So, a furnace guy walks into a heat treating facility and says, “What’s that?”
The Flame and Man
Since the invention of fire, we as upright, walking, opposing-thumb-equipped critters have been learning to control it. We have learned at the elemental level that we can change the properties of just about anything on the planet simply by exposing that item or material to the flames. Certainly, we hold fire as one of our most fascinating benefits of our existence.
Yet, in the grand scheme of things, we are just now really learning to control at levels that our Neanderthal cousins would never have conceived, and they didn’t! Conceive the possibilities, that is. I mean, for the first 400,000 years of our human existence, (that’s a mindblower, isn’t it?), fire had four basic purposes: warmth, light to see in the dark, protection from predators/enemies, and to cook our food. Later, we discovered that by heating up the tip of certain sticks, you could make the stick useful over a longer time. It didn’t wear out as fast. And from there we figured out ways to change other materials at our behest by using the flame. Weapons and tools followed.
In the bigger picture, we only have figured out the really cool uses in the last 5,000 years — and the really, really cool stuff in the last 300 years. So, the learning curve for us has been relatively late when it comes to the heat and the flame and the ability to understand it — to really control it.
Furthering the Science of Heat
How did we get to this stage of significant control over temperatures and systems that would melt a Cro-Magnon’s noodle right there in his big ol’ skull? We used our ever-developing brains. We used intelligence to advance the art of using the flame. Others before us thought their way into our present-day future. Shouldn’t we keep the ball rolling? Isn’t this ever-evolving commitment to responsible use of the flame what we need to do? We accept the gift of those before us and strive to improve on it for the upcoming iterations of humankind. Idealistic? I think not.
The premise of temperature is basically fixed. We can put it in a furnace, we can put it in a vacuum, we can melt the very rocks our planet is made from. So, let’s use the very latest available knowledge to further the science of heat. Let’s improve the situation, both at work and personally, by using our brains and by learning about what is going on with the furnaces, the parts, the fuels, and all the methods of heating. Let’s keep learning about the latest technologies. Let’s actually control this wondrous element.
To do that, we must embrace the knowledge, we have to know what we are looking at. We need to know the history and have a vision for the future. We need to teach and be taught.
Learning the Industry
If you or your reports need to get up to speed with our industry, indeed our very science — GO TO SCHOOL! The fact you are even reading this publication shows that you are open to learning. Let’s ace the test!
Heat Treat Today runs a drink-from-the-firehose learning experience calledHeat Treat Boot Camp. You can learn the latest and greatest technologies and new technologies on the horizon in heat treating. Send yourself, send your people.
The Metal Treating Institute (MTI) runs an online certification school that teaches the ins and outs of the heat treating industry. The Industrial Heating Equipment Association (IHEA) runs an annual Combustion Seminar. Almost all the major furnace and equipment suppliers offer seminars on their specialty niche.
SECO/WARWICK produces a Global Training Seminar on continuous improvement and heat treating
Can-Eng offers analysis of specific inquiries
Ajax Tocco will come to your facility to conduct the latest schooling on your equipment
All you must do is decide that you are going to continue to learn more. How can you not with these kinds of services around you?
Don’t forget Safety. National Fire Protection Agency (NFPA) seminars are available from NFPA themselves. Industry experts who have certified trainers, like Rockford Combustion, also offer multi-day seminars on equipment safety.
I can attest to the effectiveness of these kinds of learning commitments. I have been both a student and a teacher at some of the aforementioned seminars. The scope of learning can be broad or focused. It’s up to us to keep mentally expanding, so that the lessons learned don’t get lost, and the future technologies get a fair review.
I have been watching with interest how over the last 25 or so years precise control over combustion has been evolving. The major controls and process monitoring companies have been striving to gain precise control and safety on furnace equipment for years. I might add, they have been successful in varying degrees, and safety and maintenance have improved greatly.
I just spoke recently with a company in Erie, Pennsylvania. They have developed a program that monitors each individual burner. Not only does it tell if the burner is running, but if there has been a component failure, if the burner is out of tune, it can self-correct, and if there is a failure, they shut it off. Oh, and they do that for you, from THEIR office. The technology just grows and grows, doesn’t it?
So, I know some of you were wondering where I was going with the Caveman intro, and some of you probably would have preferred that I kept going up to the point where we were cooking mammoth steaks on sizzling rocks with our Cro-Magnon buddy. But we are better than him, and we need to keep proving that. Don’t you think?
Besides, this is the final month before school is out for the summer. Let’s give education a nod here.
I am sorry if I did not mention your company, no slight intended. If so, contact your customer base to alert them to any learning experiences that may be available.
Keep learning. Until next time…
About the Author
Jim Roberts President US Ignition
For More Information: Contact Jim Roberts at jim@usignition.com.
A global supplier of equipment, systems, and digital solutions for several manufacturing sectors recently announced that it has acquired Bloom Engineering, Inc, a provider in industrial heating applications. The company will join the Freight & Industrial Components Group at Wabtec Corporation, which serves the freight and transit rail industries and is a worldwide leader in the decarbonization of freight rail.
Mike Fetsko President Freight & Industrial Components Group Wabtec Corporation
This acquisition strengthens Wabtec’s heat transfer and energy solutions, integrating Bloom’s advanced technologies in burners, combustion systems, and overall services for industrial and process heating applications. Both companies are headquartered in Pittsburgh, PA.
“This is another exciting addition to Wabtec,” said Mike Fetsko, president of Wabtec’s Freight & Industrial Components Group. “Bloom Engineering is a great fit within our heat transfer and energy solutions business, and we already serve many of the same customers. Our shared vision toward driving customer productivity within their industrial processes will enable us to deliver a more comprehensive portfolio for our customers to operate more efficiently and sustainably.”
In addition to supplying solutions for the freight and transit rail industries, Wabtec also serves the mining, marine and industrial sectors. The acquisition is expected to provide increased value to its worldwide customer base.
The press release is available in its original form here.
Today’s News from Abroad installment highlights more carbon-cutting trends from the steel industry, ranging from robots in the cast house to recycling best practices.
Heat Treat Today partners with two international publications to deliver the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat. heat processing, a Vulkan-Verlag GmbHpublication, serves mostly the European and Asian heat treat markets, andFurnaces International, a Quartz Business Media publication, primarily serves the English-speaking globe.
Robots Bring Safety to Casting
Primetals Technologies’ new customized LiquiRob robotics system in operation at Siam Yamato Steel’s Map Ta Phut plant
Source: Primetals Technologies
“Thai steel producer Siam Yamato Steel has implemented a new robot concept from Primetals Technologies, including LiquiRob, at its steelworks in Map Ta Phut . . .. Thanks to the robotics solution, safety and occupational health in the steelworks have significantly improved. Previously, workers who manually operated the shadow tube had to stand directly next to the distributor and the stream of steel flowing out of the ladle. In the case of a so-called ‘frozen pan.’”
CELES EcoTransFlux™ brings green high heating abilities to the induction heating technology.
Source: Furnaces International
“Nippon Steel Stainless Steel Corporation and Sojitz Group met with our induction team at Fives headquarters in Paris for a detailed design review of the transverse flux induction heating system. CELES EcoTransFlux™ is an induction heating technology with very high heating rates at extremely high temperatures, and a compact footprint. It also has a minimal environmental footprint, making it beneficial for steelmakers to improve their carbon, stainless or electrical steel production.”
EAGP members signed an agreement to engage in a standardisation project for beverage cans.
Source: Anrita1705/Pixabay
“Four leading flat-rolled aluminium manufacturers and members of the European Aluminium Packaging Group (EAPG), Constellium, Elval, Novelis and Speira, have signed an agreement to engage in a standardisation project to maximise the recycled content levels of the beverage can and thus substantially lower carbon emissions, focused on increased recyclability of the can end.”
Mini-Mill Investment Transforms Future for Swedish Metal Manufacturer
Fossil-free mini-mill
Source: Furnaces International
“SSAB’s Board of Directors have taken the decision to proceed with the next step in SSABs transition, building a state-of-the-art fossil-free mini-mill in Luleå, Sweden. When completed SSAB will close the current blast furnace-based production system. This will reduce Sweden’s CO2 emissions with 7% in addition to the 3% from the Oxelösund mill conversion.”
A long-term test of high-efficiency and ultra-low-emission burner technology from WS Wärmeprozesstechnik at Waelzholz demonstrated that hydrogen can be used as a fuel gas to heat silicon strip lines.
Energy-efficient and low-emission heating of silicon strip lines using hydrogen as a fuel was the focus of an extensive test C.D. Wälzholz GmbH & Co. KG successfully completed together with WS Wärmeprozesstechnik in 2022.
As early as summer 2021, WS delivered several patented FLOX® burners for the installation in an existing silicon strip line. This line uses SiSiC radiant tubes to heat the furnace to a temperature of approximately 1922°F. After commissioning, the WS burners successfully operated with 100% hydrogen for one year.
The long-term test showed that a switch to hydrogen as a fuel is very possible for the furnace under investigation. Commenting on the possibility of such a switch, Mr. Peter Höfinghoff, expert for thermal process engineering in the technical office at Waelzholz, concluded: “Even after a year of operation, the burners are running very well and without faults. We were able to sufficiently demonstrate that by using WS burners, a conversion to hydrogen is technically feasible without any problems.”
With the findings from the test operation, the company is laying a foundation stone for the future hydrogen strategy at its headquarters in Hagen.
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Dr.-Ing. Joachim G. Wünning President WS Wärmeprozesstechnik GmbH
thyssenkrupp Steel, a steel manufacturer with North American locations, recently inaugurated its newest hot-dip galvanizing line 10 (FBA 10) in Dortmund, Germany. The plant has a total of three vertical strip-processing lines and is a location for annealing and surface finishing of steel strip.
thyssenkrupp Steel, by using modern regenerative burners from WS Wärmeprozesstechnik GmbH (with Ohio, U.S., and Renningen, Germany locations) in double-P radiant tubes, will save between 15% and 30% fuel as compared with conventionally heated furnaces. The patented FLOX® combustion process helps achieve low NOx emission values. The heating system is set for a later switch to green fuels such as hydrogen.
"All continuously operated strip lines are . . . suited for a future with green combustion gases," says Dr.-Ing. Wünning, President of WS Wärmeprozesstechnik GmbH.
We will explore the ever-popular subject of how to make money the easy way. Well, better stated: How to save some money, but at the end of the year the result is the same.
This column is a Combustion Corner feature written by John Clarke, technical director at Helios Electric Corporation, and appeared inJune 2022 Heat Treat Buyers Guide print edition.
If you have suggestions for savings opportunities you’d like John to explore for future columns, please email Karen@heattreattoday.com.
John B. Clarke Technical Director Helios Electric Corporation Source: Helios Electric Corporation
For our discussions, we will assume that we are operating a continuous heat treat furnace that processes work at 1600°F. The furnace currently consumes 2,000 SCFH of 1000 BTU/SCF natural gas and operates 8,000 hours per year. With today’s natural gas at 8.00 USD per 1 mmBTU (1 mmBTU = 1,000 SCF of natural gas), our furnace’s annual operating cost is:
Using our trusty combustion analyzer that provides a readout of the oxygen present in the flue products, we quickly determine the fuel contains 6% O2 (measured by volume, dry basis). The “volume/dry basis” is the most common value measured by handheld combustion analyzers. We measure the temperature of the flue products at 1700°F. Our burner and/or furnace specifications say the system should be operated at 3% O2. How much can we save by adjusting the burner(s) on this furnace?
Table 1 below provides savings numbers that result when non-recuperated burners are returned to 3% O2.
If we read where the exhaust temperature row intersects with our column for our starting O2 volume in the flue products, we see the resultant savings will be 13.9%:
We chose 3% O2 in the flue products (around 15% excess air) because radiant tubes and direct fired systems can commonly operate at this level with little CO or soot generation. A simple combustion analyzer can be purchased for a few thousand dollars and the labor required to make these adjustments is generally under a day. The payback period for this maintenance investment is measured in weeks, even if it requires the purchase of new tools.
There may be an added benefit we receive when adjusting the furnace. We may have an opportunity to increase the throughput, so perhaps production can be increased while fuel costs are reduced.
Table 1 can be used for other specific conditions, so keep it handy. Next month, we will explore the savings resulting from recuperation or pre-heating the air.
Recuperation projects are more complicated and require greater investments, but they are becoming increasingly critical for heat treaters working to stay competitive in our new reality of dramatically higher natural gas prices.
About the Author:
John Clarke, with over 30 years in the heat processing area, is currently the technical director of Helios Corporation. John’s work includes system efficiency analysis, burner design as well as burner management systems. John was a former president of the Industrial Heating Equipment Association and vice president at Maxon Corporation.
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Tata Steel will receive an IIOT (industrial internet of things) solution for their industrial furnaces. This solution is designed to reduce emissions and increase furnace throughput by measuring, maximizing, and maintaining energy input through the combustion process.
PSNERGY LLC's Total Combustion Solution consists of combustion monitoring and alerting, which delivers simple and actionable combustion performance reports resulting in reduced equipment downtime, as well as radiant tube inserts to absorb and radiate energy into the load. This package is set to increase productivity and reduce emissions at Tata Steel furnaces. The project will be completed by the end of Q2 in 2022.
Find heat treating products and services when you search on Heat Treat Buyers Guide.com
For Ovako, a centuries old manufacturer of engineering steel, innovative approaches to producing their product has taken the form of electrifying their roller hearth furnaces over the course of the past decade.
The process of converting to electric heating began in 2014, each furnace installed with up to 86 Tubothal® metallic heating elements from Kanthal. Now, 14 roller hearth furnaces are electrified. The estimated CO2 savings is around 1,400 to 2,000 tons per year per furnace.
“[In] our heat treatment shop in Hofors,” shares Anders Lugnet, a furnace technology specialist at Ovako (pictured above), “we originally had around 450 gas burners, and there was always a problem somewhere in one of them. Since replacing them with 300-odd Tubothal® elements, the daily maintenance is simply not there. Occasionally, an element needs to be replaced, but it is nothing compared to the way it was.”
He continues that, previously, NOx and CO2 emissions were problematic. But with green electricity, emissions are zero, and with no flue-gas losses, total efficiency has improved significantly.
We will explore the ever-popular subject of how to make money the easy way. Well, better stated: How to save some money, but at the end of the year the result is the same.
