Press Facts
Efficient furnaces for hot dip galvanizing
Zink Körner cuts energy consumption in
galvanizing by 15 percent
Controlled waste gas flow takes the heat in the furnace exactly where it is
needed.
Hagen, Germany, May 9, 2017 The new RECU-CHANNEL recuperative
heat exchanger system may achieve energy savings of more than 15
percent in batch-parts, wire and small-parts galvanizing. In typical
batch-parts galvanizing plants, this may result in approx. 30,000 euros
saved on natural gas costs every year.
For galvanizing at temperatures between 450 and 460 °C, Zink Körner has
developed its new RECU-TEC hot dip galvanizing technology, which allows
the input energy to be recovered directly in the furnace. These furnaces are
equipped with a steel tank and natural-gas fired flat flame burners.
Innovative recuperation technology
The new RECU-CHANNEL recuperative heat exchanger system heats the
kettle very uniformly and exactly to the required temperatures. Operation of
the furnace requires more than 15 percent less energy than traditional
systems. Thus, more than 30,000 euros per year can be saved on natural
gas costs, for example, in case of a batch galvanizing plant with an average
through-put rate of 6 tons per hour.
While in conventional systems without RECU-CHANNEL technology the
waste gas collects at the top, RECU-CHANNEL systems suck the waste gas
from below in a controlled way allowing the waste gas to flow downwards
past the outside surface of the kettle wall. Thus the waste gas transfers to
the lower part of the tank exactly that amount of energy that is required for
the process.
The channels are arranged at both long sides of the furnace extending along
their complete length. Thus the waste gas travels long distances, giving it
more time for the heat transfer. Using the residual heat in the RECUCHANNEL to preheat the combustion air leads to a further increase in
furnace efficiency.
The result: While the waste gas temperature of furnaces without RECU-TEC
usually reaches 550 °C or more, the waste gas temperatures of the new
furnaces are always below 400 °C, even in case of full load operation. This is
a clear indication that the input energy is extremely efficiently used.
Highly efficient burner technology
Zink Körner has developed the modulated KÖRNER FL 15/80 flat flame
burners specifically for the heating of steel kettles. These burners feed just
as much energy to the galvanizing furnace as necessary at any point in time.
Unlike intermittent burners, they operate with a combustion air ratio λ of only
1.10 – hence with much less surplus air than usual. Their efficiency is 10 to
Document1
www.vip-kommunikation.de
1
20 percent higher and gas consumption correspondingly lower than that
achievable by burners operating with a ratio of, let’s say, 1.20.
Additionally, the modulating operation avoids short-term consumption peaks.
This saves on gas procurement costs as the gas suppliers calculate their
provision fees based on the peak load of the furnace.
Each of the diffuser plates of the new burners is supported by three rods fix
mounted to the burner port. This arrangement achieves constant pressure
conditions which allow the flame to be adjusted with utmost precision. For
the user this provides the benefits of ideal combustion ratios and minimal gas
consumption.
The burners are installed along the long sides of the furnace at two thirds of
the furnace height (from the bottom). At that position, the heat requirement is
highest due to the heat loss at the bath level.
530 words including introduction
Contact:
Zink KÖRNER GmbH
Dipl.-Ing. Peter Kordt
Profilstraße 9
D-58093 Hagen/Germany
Fon: +49.2331.800 6-0
Fax: +49.2331.800 6-10
www.koerner-hagen.com
E-mail: [email protected]
Press contact:
VIP Kommunikation
Dr.-Ing. Uwe Stein
Dennewartstraße 25-27
D-52068 Aachen/Germany
Fon: +49.241.89468-55
Fax: +49.241.89468-44
www.vip-kommunikation.de
E-mail: [email protected]
Figures and captions
Fig. 1: The RECU-TEC principle: The
flame (yellow) is deflected by
the diffuser plate, and the hot
gas is sucked from below.
File name:
Zink Körner RECU-TEC Prinzip.png
Document1
www.vip-kommunikation.de
2
Fig. 2: A galvanizing furnace for cable
support systems
File name:
Zink Körner Stück_2.jpg
Photo credits: Zink Körner
About Zink Körner
Zink Körner GmbH designs and manufactures the complete array of hot-dip
galvanizing equipment for single parts, tubes and pipes, miscellaneous small
parts and centrifugal parts.
The supply range encompasses complete galvanizing plants, including
pretreatment and handling equipment. The company provides design,
engineering, manufacture, installation, commissioning and after-sales
services. Zink Körner maintains a worldwide network of branches and
licensees.
Zink Körner has launched many pioneering developments during its
company history. For example, as early as at the beginning of the 1970s the
company built the first automated centrifugal galvanizing plants, which have
markedly improved the quality of the end products and the energy efficiency
of the galvanizing process. The company took another innovative move by
developing dedicated burner technology for hot-dip galvanizing applications.
Zink Körner is a company of the Körner Group, which was established in
1928. Thus the Group builds on more than 80 years of experience in
industrial furnace technology and auxiliary equipment.
Within the Group, Wire Körner GmbH designs heat treatment equipment for
wire and narrow strip. TVT Kordt GmbH develops plants for thermal process
technology, with a focus on industrial furnaces for the heat treatment of
steels, special steels and non-ferrous metals.
Document1
www.vip-kommunikation.de
3