heat treat sustainability

Heat Treat Radio #114: Decarbonization Demystified at IHEA’s SUMMIT

Listen as Jeff Rafter, vice president of sales and marketing at Selas Heat Technology and current IHEA president, discusses the upcoming IHEA Decarbonization SUMIMIT with Doug Glenn. Scheduled for October 28-30 in Indianapolis, Indiana, the summit will address the challenges and opportunities of decarbonization for manufacturers. Jeff highlights IHEA’s nearly 100-year history in industry education. The event will feature keynote speakers from the DOE, Oak Ridge National Laboratory, and John Deere, with a mix of technical and business content aiming to provide practical strategies for energy management and sustainability. Learn more in this episode of Heat Treat Radio, and learn more about this episode sponsor, IHEA, and their event at summit.ihea.org. 

Below, you can watch the video, listen to the podcast by clicking on the audio play button, or read an edited transcript.




The following transcript has been edited for your reading enjoyment.

The IHEA Decarbonization Summit (01:03)

Doug Glenn: Jeff, when and where is the summit? And what was the driving force behind deciding to do this event?

Jeff Rafter: The IHEA Decarbonization SUMMIT will be at the Conrad Hotel in Indianapolis, Indiana, beginning on Monday, October 28, and ending Wednesday, October 30.

The drive to create this event arose because the IHEA membership had often commented on, and lamented, the frequent inquiries they get from the client base across all sectors of manufacturing; clients are looking for clarification on the ongoing changes of the U.S. energy infrastructure and, specifically, how to manage the requirement to reduce carbon dioxide emissions.

There is a lot that is changing quickly in the U.S. energy infrastructure around renewables, electrification, and low carbon fuels. he IHEA board felt that it was essential to assist manufacturing members by trying to clarify these topics in an interesting event that presented the information objectively and provided a diverse array of all the decarbonization pathways available to manufacturers today.

IHEA’s Qualifications (02:36)

Doug Glenn: For those who might not know what IHEA is, what makes it uniquely qualified to present such a summit?

Jeff Rafter: I am proud to say that IHEA is a very unique organization. Many trade organizations do not have the long-standing success in supporting members that this organization has. The composition of IHEA, which is close to 100 years old, was originally made up of heating appliance and heating component manufacturers, who have spent most of our history focused on industry education as a service to all the member companies.

We felt that this was the perfect organization to take up the topic of sustainability and decarbonization because we are education focused. From that background and that bias, we are leveraging thousands of years of experience over a broad array of manufacturing options from traditional fossil fuels through electrification. Our member companies provide a very strong basis to deliver real-world examples of how to deal with reducing CO2 emissions.

Doug Glenn: And if I am remembering correctly, IHEA actually has a standing history of cooperation and working with the DOE on different things in the past, correct?

Jeff Rafter: Very good point, Doug. If you look back in history, before “CO2 reduction” and “decarbonization” became buzzwords, we spent a lot of similar efforts working with government organizations, research laboratories, and third-party organizations around topics of NOx reduction and trying to create a cleaner basis of industrial, manufacturing, and energy. In addition, we have always spent our time helping with business concerns regarding efficiency, not only operating successfully heating processes and appliances, but also making manufacturing more cost effective.

Keynote Speakers (04:44)

Doug Glenn: And speaking of the DOE, I see that there are some pretty high-profile speakers coming. The keynote speaker is Dr. Avi Shultz, from the U.S. DOE, and he is on the Industrial Decarbonization Initiative. Other speakers include Paulomi Nandy from Oak Ridge National Lab, Jeff Kaman from John Deere, and Tim Hill from Nucor. Can you give us a sense of what these folks will be talking about?

Jeff Rafter: Doug, we are very excited to have the diverse mix of speakers that will make up the summit presentations. With Dr. Schultz and Miss Nandy, we are very excited to be providing a third-party opinion — government organizations and research laboratories — and they will be presenting on their views of the trends for the future of sustainability and decarbonization.

When we move to some of the other presenters like Tim Hill from Nucor and Mr. Kaman from John Deere, we also wanted members and attendees to take away from the summit real-world experience. These are not imagined or planned changes. We wanted companies that had actual experience with decarbonization — who had even taken actions towards net-zero positions — to share with attendees exactly how they approached the challenges.

Because, of course, some of the issues around sustainability are that it comes at a cost.

And how do you fund that? How do you research that? Where do you look for grants, and how do you make the business case towards decarbonization or any sustainability action for that matter?

Finally, adding to those two bodies of participants, we have a number of presenters speaking about real-world solutions today. IHEA’s view on decarbonization and sustainability is that there is a very broad set of pathways that you can take today with inexpensive, readily available technologies all the way out to longer term solutions like full electrification of processes.

There is more than one way to approach this challenge and do the responsible thing in manufacturing, which is to address our CO2 production globally.

Is Electrification the Only Answer? (07:25)

Doug Glenn: You mentioned electrification. When people hear decarbonization or sustainability, they often think electrification. There may be a lot of people listening saying, “I am primarily combustion. Should I be going?” Are only electrification solutions going to be presented? Or are combustion solutions going to be presented as well to help with the decarbonization?

Jeff Rafter: The answer to that question is, “Yes, you should be going, regardless of whether your focus and your background is in traditional fossil fuel combustion or electrification.”

The summit will contain a very balanced approach of different technologies, presented with no bias. The goal of this summit is providing education to help business leaders make better decisions around their energy management and their environmental concerns.

With that said, when we look at the body of what is available in the agenda, electrification is an important topic. But as a lot of people recognize, some portions of electrification are just relocating to a different fossil fuel further away from the point of use whilst other electrification options linked to renewable energy sources truly can come close to net-zero production of CO2.

IHEA’s view is that there are many sustainability pathways that we can all investigate or pursue.

Some pathways maintain fossil fuel basis. Some industrial processes will be challenged to move to an electric heating source. And then for other processes, electrification is the cat’s meow. So it is that broad sweep of diverse technologies that everyone needs to be educated on to make better decisions when the time comes.

Who Should Attend the Summit? (09:21)

Doug Glenn: How technical will the summit be; do I need to know heavy engineering, metallurgy, and things of that sort? And who should come?

Jeff Rafter: Traditionally, a lot of IHEA’s educational content has been directed at a technical audience; it was technical education about how various energy sources and heating appliances work, how to comply to code, and how to approach the application of that equipment safely. In this particular summit, we have changed course a bit in that we did not want this event to be a technical conference.

The idea of this summit was to make it a business conference because that is where most of the challenges exist when we look at sustainability efforts.

The content that will be presented is a pleasant mix of some technical topics because we have to get a rudimentary understanding of how these different technologies work. However, we are spending just as much time in the presentations addressing business concerns: How do you fund these various actions? Where can you find available grants? What are real-world examples of how other companies have approached sustainability or have begun an initiative internally? How do you get the support and the decision-making decided while moving in the right direction? When you look at the agenda that will be posted on the IHEA website, you will see that the topics range broadly from some technology presentations to real-world business concerns and how to make those business decisions.

Agenda for IHEA Decarburization Summitt, Monday – Wednesday, October 28-30, 2024, in Indianapolis, Indiana

Doug Glenn: How much fun have you had putting this summit together?

Jeff Rafter: I would happily report it has been a tremendous team effort.

I am very proud to say that a lot of IHEA member companies and third parties have stepped up to help us construct this event. We are really looking forward to it being a valuable event that provides a lot of information and important takeaways for participants.

Doug Glenn: I know you have put a lot of work into it. I have watched you do this over the last year and a half, and you have done a great job coordinating it.

Closing Remarks (12:34)

Jeff Rafter: I would just like to say in closing, for anyone who is thinking about coming to the IHEA Decarbonization Summit, please do. This is a very important topic for manufacturers, and you really need to take the approach of not waiting. It is time to get in front of changes in our energy infrastructure and the need to decarbonize some manufacturing processes. This is a great way to get educated and start your plan.

Doug Glenn: And I did remember one other motivation: If you are looking to stay at the hotel where the summit is held, the cutoff date for the hotel (you can still get into the summit even if you do not hit this cutoff date) is October 7th. So anyhow, appreciate it. Jeff, thanks very much for your time.

About The Guest

Jeff Rafter
Vice President of Sales and Marketing
Selas Heat Technology Company, LLC
Source: Selas Heat Technology

Jeff Rafter is vice president of sales and marketing for Selas Heat Technology in Streetsboro, Ohio, and has a rich history in the combustion industry, including Maxon Corporation. Jeff has 31 years of industrial experience in sales, research and development, and marketing; combustion application expertise in process heating, metals, refining, and power generation; and 13 years of service on NFPA 86 committee. He holds patents for ultra-low NOx burner design. Additionally, his company, Selas, is an IHEA member, and Jeff is the current president of IHEA as well as one of the driving forces/coordinators behind the upcoming Decarbonization Summit at the Conrad Hotel in Indianapolis, October 28-30.

Contact Jeff at jrafter@selas.com.


Search Heat Treat Equipment And Service Providers On Heat Treat Buyers Guide.Com


Heat Treat Radio #114: Decarbonization Demystified at IHEA’s SUMMIT Read More »

Advantages of Laser Heat Treatment, Part 2: Energy Efficiency, Sustainability, and Precision

A discussion of laser heat treating begun in Heat Treat Today’s Air & Atmosphere 2024 print edition would not be complete without highlighting key sustainability advantages of this new technology. In this Technical Tuesday installment, guest columnist Aravind Jonnalagada (AJ), CTO and co-founder of Synergy Additive Manufacturing LLC, explores how sustainability and energy-efficiency are driven by precision heat application and minimal to zero distortion. The first part, “Advantages of Laser Heat Treatment: Precision, Consistency, and Cost Savings”, appeared on April 2, 2024, in Heat Treat Today, as well as in Heat Treat Today’s January/February 2024 Air & Atmosphere print edition.

This informative piece was first released in Heat Treat Today’s May 2024 Sustainability Heat Treat print edition.


Laser heat treating is a transformative process that promises superior performance and sustainable practices. Laser heat treating epitomizes precision in surface heat treatment techniques, targeting localized heating of steel or cast-iron components. Laser radiation raises the surface temperature of the metal in the range of 1652°F to 2552°F (900°C to 1400°C), inducing a transformation from ferritic to austenitic structure on the metal surface. As the laser beam traverses the material, the bulk of the component self-quenches the heated zone. During this process, carbon particles are deposited in the high temperature lattice structure and cannot diffuse outward because of quick cool down resulting in the formation of hard martensite to a case depth up to 0.080” (2 mm), crucial for enhancing material properties.

Sustainability through Energy Efficiency

Contact us with your Reader Feedback!

When considering the energy consumption of a typical laser heat treating operation, it’s essential to acknowledge the continuous advancements in laser technology. Modern laser heat treating systems integrate high-power lasers, water chillers, and motion systems, such as robots or CNC machines. With a typical wall plug efficiency of around 50% for diode lasers, these systems represent a significant improvement in energy utilization compared to conventional methods. The typical energy consumption cost for running a 6 kW laser heat treating system is $20-$30/day. The calculation is based on an 8-hour shift with a duty cycle of 80% calculated at national average electric cost of 15.45 cents/kilowatt-hour.

Self-Quenching Mechanism

Laser heat treating operates on the essential principle of self-quenching, leveraging the bulk mass of the material for rapid cooling. This eliminates the dependence on quenchants required in flame and induction heat treating processes, further reducing environmental impact and operational costs.

Precision and Minimal Distortion

At the heart of laser heat treating lies its sustainable and energy-efficient attributes, driven by two fundamental features: precision heat application and minimal to zero distortion of components post-heat treatment. When compared to the conventional methods such as flame and induction hardening, laser heat treatment offers significantly localized heating. This precision allows for targeted heat treatment within millimeter precision right where the hardness is needed, optimizing energy utilization and operational efficiency. Furthermore, the high-power density of lasers enables hardening with minimal to zero distortion, eliminating or reducing the need for subsequent machining operations like hard milling or grinding.

Case Study image; 16 small boxes of auto parts undergoing die machining, laser heat treat; blue inset box
Comparison of the die construction process before and after laser hardening
Source: Autodie LLC

A Case Study of Laser Heat Treating in Automotive Stamping Dies

The image above identifies process steps typically involved in construction of automotive stamping dies. During the process of manufacturing automotive stamping dies, the cast dies are first soft milled, intentionally leaving between 0.015” and 0.020” of extra stock material on the milled surfaces. This is done to account for any distortions that will result from the subsequent conventional heat treatment processes such as flame or induction. After heat treating, the dies are then hard milled back to tolerance and assembled.

In the laser heat treating process, by contrast, dies are finish machined to final tolerance in the first step and then laser heat treated without distortion. No secondary hard milling operation is necessary. Typical cost savings for our automotive tool and die customer exceeds over 20% due to elimination of hard milling operation. Total energy reduction is significant, although not computed here. This may result in savings if carbon credits become monetized.

Laser heat treating’s precision, efficiency, and minimal environmental footprint position it as an environmentally friendly option for heat treat operations. As industries continue to prioritize sustainability, laser heat treating may set new standards for excellence and environmental stewardship.

About the Author:

Aravind Jonnalagadda
CTO and Co-Founder
Synergy Additive Manufacturing LLC
Source: LinkedIn

Aravind Jonnalagadda (AJ) is the CTO and co-founder of Synergy Additive Manufacturing LLC. With over 15 years of experience, AJ and Synergy Additive Manufacturing LLC provide high-level laser systems and laser heat treating, specializing in high power laser-based solutions for complex manufacturing challenges related to wear, corrosion, and tool life. Synergy provides laser systems and job shop services for laser heat treating, metal based additive manufacturing, and laser welding.

For more information: Contact AJ at aravind@synergyadditive.com or synergyadditive.com/laser-heat-treating.


Find Heat Treating Products and Services When You Search on Heat Treat Buyers Guide.com


Advantages of Laser Heat Treatment, Part 2: Energy Efficiency, Sustainability, and Precision Read More »

US DOE Strategy Affects Heat Treaters

As heat treaters strive for a sustainable future, pressure mounts to make the right choices while running commercially viable operations. This guest column by Michael Mouilleseaux, general manager at Erie Steel, Ltd., explores how and why heat treat operations are now coming under the focus of the U.S. Department of Energy.

This informative piece was first released in Heat Treat Today’s March 2024 Aerospace print edition.


The iron and steel industry contributes approximately 2.1% of energy-related CO2 emissions from primary sectors in the U.S. These statistics may seem insignificant or far removed, but the federal government has now determined that heat treating is a significant contributor and has set in motion critical changes for U.S. heat treaters.

Background

Click to share your Reader Feedback!

On December 8, 2021, President Joe Biden issued an executive order that committed the federal government to “lead by example” in U.S. efforts towards carbon-free and net zero emissions solutions. Since then, the executive has delegated the Department of Energy (DOE) and the Environmental Protection Agency (EPA) to spearhead these initiatives aimed at reducing greenhouse gas emissions (GHGE) and promoting energy efficiency across various sectors of the U.S. economy. To support these efforts, $10,000,000,000 in incentives are being allocated for the DOE and EPA to investigate and promulgate regulations.

Specifically, the government sees the “industrial sector” as responsible for close to a quarter of all greenhouse gas emissions (GHGE); the five industries named within this sector are chemical processing, petroleum processing, iron & steel production, cement production, and food & beverage manufacturing. The DOE is leading the efforts of “supercharging industrial decarbonization innovation” and leveraging the potential of “clean hydrogen.”

Following these directives, the DOE unveiled the “Industrial Decarbonization Roadmap” in September 2022. This strategic plan will guide decarbonization efforts of the five key industrial sectors to mitigate GHGE. The four pillars are:

  • Energy efficiency
  • Industrial electrification (using green electricity)
  • Adoption of low-carbon fuels, feedstocks, and energy sources (LCFFES)
  • Carbon capture, utilization, and storage at the generated source (CCUS)

The DOE determined that process heating — accounting for 63% of energy usage within the iron and steel industry — would be the best opportunity to apply these four pillars. However, until May 2023, heat treating had not been explicitly mentioned as a target for decarbonization efforts.

Why Should Heat Treaters Care?

In May 2023, the Industrial Efficiency & Decarbonization Office — an office within the DOE’s Office of Energy Efficiency & Renewable Energy — held a symposium to refine its commitment to the decarbonization of the industrial sector. It was then that heat treating was specifically defined as a process targeted for the reduction of GHGE in the steel, aluminum, and glass manufacturing industries.

The DOE’s refined commitment focuses on two things: reduce GHGE attributable to “process heating” by 85% by 2035 and achieve net-zero CO2 emissions by 2050. To reach these ambitious goals, the DOE emphasized the importance of adopting LCFFES, green electrification, and implementing strategies that promote industrial flexibility, advanced heat management, smart manufacturing, and alternative technologies.

The potential ramifications of the DOE’s efforts on the heat treating industry are momentous. With the development of regulations to support these efforts, businesses within this sector must prepare for significant changes. The focus on green hydrogen, biofuels, and electrification, coupled with advanced technological solutions like ultra-efficient heat exchangers, artificial intelligence, machine learning, and alternative no-heat technologies, are strategies being considered for potential regulation.

Conclusion

The heat treating industry stands at a crossroads, with the DOE’s decarbonization initiatives signaling a shift to adopt cleaner energy practices. As these regulations take shape, businesses will need to adapt, investing in new technologies and processes that align with the nation’s clean energy goals. In the next column, we’ll address potential ramifications of the DOE effort for industrial decarbonization in the heat treating industry to help you be better informed and prepared.

About the Author:

Michael Mouilleseaux
General Manager at Erie Steel, Ltd.

Michael Mouilleseaux is general manager at Erie Steel, Ltd. He has been at Erie Steel in Toledo, OH since 2006 with previous metallurgical experience at New Process Gear in Syracuse, NY, and as the director of Technology in Marketing at FPM Heat Treating LLC in Elk Grove, IL. Michael attended the stakeholder meetings at the May 2023 symposium hosted by the U.S. DOE’s Office of Energy Efficiency & Renewable Energy. He will be speaking on the MTI podcast about this subject on March 5, 2024, 2:30 EST, and will present on this topic at the April 3, 2024, MTI Mid-West chapter meeting.

For more information: Contact Michael at mmouilleseaux@erie.com.

Attend the SUMMIT to find out more about the DOE’s actions for the heat treat industry.

Find Heat Treating Products and Services When You Search on Heat Treat Buyers Guide.com

US DOE Strategy Affects Heat Treaters Read More »