Wesman Furnaces

Rotary Hearth Type Furnaces For Reheating And Heat Treatment

Wesman has a full range of Rotary Hearth type Heat Treatment and Reheating Furnaces up to a capacity of 150 MTPH to offer to the Seamless Steel Pipe, Rail Wheel and Axle manufacturing and Forgings Industries. Mostly billets/blooms are placed horizontally on the hearth. Rotary hearth furnaces for vertical loading of the material can also be offered.

Two independent hydraulically operated machines are used for charging and discharging of material one at a time on the rotating hearth. Charging machine will pick-up the material from the Charge Roller Table placed at a particular location and place the material through charge door on the hearth at a predetermined location. Simultaneously, the discharge door will also open-up and the discharging machine will pick-up the hot material from the hearth and deliver the material to a discharge roller table. Both charging and discharging doors shall be driven by dedicated electro-mechanical/hydraulic drive arrangement.

Rotating hearth is fitted with adequate number of supporting rollers in two rows and move over rails anchored to the ground. Centering rollers are placed on the inner side of rotating hearth to prevent lateral displacement. Hearth rotation is made through two numbers electro-mechanical or hydraulic drive units placed at 180° apart. Hearth indexing arrangement is provided to stop hearth at stations for charging & discharging simultaneously.

The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG, Natural Gas singly or a combination of any oil or gas in case of dual fired furnaces.

To improve fuel efficiency, Recuperators for heating combustion air up to 500 deg C is provided. For customers requiring even more fuel efficiency, Wesman Regenerator burners can be offered that can give air preheat of 1000 deg C or more.

Pusher Type Reheating Furnaces

Wesman has a full range of Pusher type Reheating Furnaces up to a capacity of 150 MTPH to offer to the steel rolling industry. These furnaces can be Top Fired or Top & Bottom Fired, depending on the cross section of the charge material. Billets or slabs are charged on the hearth side by side so that it can be pushed from the charge end the discharge end by means of a electro-mechanical or hydraulic Pusher Machine. The material can be end-discharged at the opposite end or by side-discharge by an Ejector, to suit customer’s mill requirements. All machinery for automatic operation such as Slab Extractors and Pinch Rolls to suit each typical requirement is tailor made to give best results.

The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG, Natural Gas, Coke Oven gas, Blast furnace gas, Producer gas singly or a combination of any oil or gas in case of dual fired furnaces.

To improve fuel efficiency, Recuperators for heating combustion air up to 500 deg C is provided. For customers requiring even more fuel efficiency, Wesman Regenerator burners can be offered that can give air preheat of 1000 deg C or more.

All Wesman furnaces are lined with a combination of high alumina bricks backed by insulation bricks to minimize the skin temperature. High temperature ceramic fiber is also used in various locations to reduce heat losses and reduce maintenance. Roof design can be suspended type of hatch back depending on the design requirements.

Continuous Roll Down Type Heat Treatment/ Reheating Furnaces

Wesman has a full range of Continuous Roll-down type Heat Treatment/Reheating Furnaces to offer to the pipe manufacturing, aluminium and other metal industries. Roll-down furnaces are used for preheating of aluminium logs/billets and preheating of round mandrels for seamless steel tube pipe manufacturing, in addition to other preheating and heat treatment applications. Roll-down furnaces can be fuel fired or electrically heated. Skid rails are laid on hearth with slope to facilitate movement of material to discharge end by rolling under gravity. The material are charged on the hearth side by side over skid rails so that it can be pushed into the furnace by means of pneumatically/ hydraulically operated pusher mechanism. The material will be discharged at the opposite end of the roll-down furnace one at a time.

The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG and Natural Gas singly or a combination of any oil or gas in case of dual fired furnaces.

The furnace can be provided with electrical heating through heat resistant Strip/Wire/Cartridge heating elements located along with the side/back walls/roof of the furnace. The heating elements of the furnace are suitably divided into number of heating zones with each zone of having their bank of heater. The heating elements of the furnace are suitably divided into number of heating zones and can be controlled through Contactor or Thyrister based control philosophy through PID controllers.

The Roll-down Furnaces can be directly heated through Burners located behind stainless steel baffles. The roll-down furnaces will also be provided with stainless steel/mild steel baffles depending on furnace operating temperature  to allow uniform heating inside the furnace and ensure sufficient circulation of hot air through suitably sized recirculation fan assembly.

The Roll-down Furnaces are lined with high temperature grade ceramic fiber lining at the sidewalls and modules at the roof and door. The bottom hearth of the furnace is provided with combination of high alumina bricks backed by insulation bricks to minimize the skin temperature.

For electrically heated furnace, the temperature control shall be on PID based programmable control philosophy with thyristor heater controllers for better temperature control and energy efficiency. Wesman electrically heated furnaces can be offered with 100% thyristor controllers or 100% DELTA/STAR/OFF mode for higher energy efficiency.

Wesman has full capability to offer complete control and instrumentation system through PLC based or hard-wire based logic c

Wesman has a full range of pit type Heat Treatment up to a capacity of 100 MT for hardening, annealing, normalizing, carburizing, nitriding, tempering, aging and stress relieving to offer to industries like Fastener, Bearing, Forge Parts, Gears, Rolls, Strip, Wire, Piston rings etc in steel industries besides cylinder heads and pistons for Aluminum industries.

These furnaces are of circular construction with insulated cover which is hydraulically lifted/swiveled for charging or discharging the material into and from the furnace. The charge material can be loaded into the Pit furnace with the help of EOT crane or suitable loading machine. The Pit furnaces can also be offered with quenching facilities and washing machine to suit customers’ requirement.

Pit furnaces are offered with or without sealed retorts for inert/reducing atmosphere or normal oxidizing atmosphere applications. The furnaces with inert/reducing atmosphere applications will have facility for introducing atmosphere like hydro-carbon rich gas , ammonia and nitrogen into a sealed retort made of stainless steel of AISI-310/304 depending on the application temperature.  The lid is fitted with gas tight through water-cooled neoprene/silicon rubber seal for proper sealing.

These furnaces can be either electrically heated or fuel fired The electrically heated furnaces are provided with resistive strip/wire heating elements located on the sidewall of the furnace. The heating elements of the furnace are suitably divided into number of heating zones and can be controlled through contactor or thyrister based control philosophy through PID controllers. Fuel fired Pit furnaces are offered with Wesman’s high efficiency burners for Oil/Gas application supported by a full complement of combustion control system with safety devices.

Hot air circulation inside the furnace is made by efficient centrifugal or axial type recirculation fan which can be with two speed motor or with VVFD drive. Pit furnaces are lined with ceramic fibre block/module at side wall and lid cover. Bottom hearth will be lined with refractory bricks backed by insulation bricks, specially designed to withstand load to minimize the skin temperature.

Wesman has full capability to offer complete control and instrumentation system through PLC based or Hardware based logic controls.

Walking Hearth Type Reheating Furnaces

Wesman has a full range of Walking Hearth type Reheating Furnaces up to a capacity of 150 MTPH to offer to the steel rolling industry. Billets or slabs are charged on the hearth at required spacing through side door over water cooled rollers, will move from charging to discharging end by means of hydraulically driven walking hearth mechanism and are discharged through the side door over water cooled rollers or with the help of ejector. The furnaces can also be designed for end-charging with the help of charge pusher and end-discharging by extractor to suit customer’s requirement. All machinery for automatic operation such as Extractors, Ejectors and Pushers to suit each typical requirement is tailor made to give best results.

Suitable number of moveable refractory lined walking hearths are provided across the width of the furnace for movement of material from charging to discharge end. Hydraulically operated walking hearth mechanism is provided for material movement from one station to the another.

The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG, Natural Gas, Coke Oven gas, Blast furnace gas, Producer gas singly or a combination of any oil or gas in case of dual fired furnaces.

To improve fuel efficiency, Recuperators for heating combustion air up to 500 deg C is provided. For customers requiring even more fuel efficiency, Wesman Regenerator burners can be offered that can give air preheat of 1000 deg C or more.

Continuous Tray Pusher Type Heat Treatment Furnaces

Wesman has a full range of Continuous Tray Pusher type Heat Treatment Furnaces up to a capacity of 10 MTPH to offer to the Automotive Castings, Forgings and other metal industries. These Heat Treatment Furnaces comprise of Tray Pusher type Hardening and Tempering Furnaces with Quenching facilities for polymer or oil as per the process requirement.


WHF Bhopal - Tray pusher furnaceTrays loaded with material are charged on the hearth over side by side skid rails so that it can be pushed into the furnace by means of pneumatically/hydraulically operated pusher mechanism. Trays with material will be discharged at the opposite end of hardening furnace and will be placed over the cradle of the quenching system, which will immerse the charge tray with the material into the quench tank. After the quenching cycle is over, cradle will lifted up from the quenching tank and will be moved forward to the charge side of tempering furnace by means of electro-mechanical discharge roller conveyor. Trays with material, one by one, will again be charged on the hearth of the Tempering Furnace side-by-side so that it can be pushed from charging end to the discharging end by means of pneumatically/hydraulically operated pusher mechanism. Trays loaded with material one by one can be end discharged at the opposite end of the tempering furnace in the unloading area where the material can be unloaded by means of hoist or tilting mechanism or manually.  The empty trays can be brought to loading area of the Hardening Furnace for the next cycle over conveyors.


The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG and Natural Gas singly or a combination of any oil or gas in case of dual fired furnaces.


The Hardening Furnace is provided with Recuperator to improve fuel efficiency, the Recuperator will heat the combustion air up to 200 deg C and the pre-heated air will be supplied to the burners.


As an alternative, the furnaces can be offered with electrical heating through heat resistant Strip/Wire/Cartridge heating elements located along with the side/back walls/roof of the furnace. The heating elements of the furnace are suitably divided into number of heating zones with each zone of having their bank of heater. Each bank heater shall be connected either in STAR/DELTA or Parallel STAR/DELTA groups to have minimum number of heater per phase per group.


The Tempering Furnaces can be directly heated through Burners located behind stainless steel baffles. To allow uniform heating inside the tempering furnace and ensure sufficient circulation of hot air, suitably sized recirculation fan assembly will be provided. Baffles fabricated from stainless steel sheets of AISI-304 are installed to guide the recirculation of hot gas inside the furnace. These baffles are suitably anchored with heat resistant studs from sidewalls and roof.


The Hardening Furnaces are lined with high temperature grade ceramic fiber lining at the sidewalls and modules at the roof and door. The bottom hearth of the furnace is provided with combination of high alumina bricks backed by insulation bricks to minimize the skin temperature.


The Tempering furnaces can be of Double Wall construction with inner SS 304 and outer MS or with Cera board with back up ceramic fiber lining at the sidewalls roof and door. The bottom hearth of the furnace will be provided with combination of medium grade alumna bricks backed by insulation bricks to minimize the skin temperature.

Spring Heat Treatment Furnaces

Wesman has a full range of spring Heat Treatment Furnaces up to a capacity of 15 MTPH to offer to the Coil and Leaf Spring Manufacturing Industries. These Furnaces comprise of Hardening and Tempering Line. The Hardening Furnace can be Walking Beam Type with Quenching Facility for Polymer or Oil as per the process requirement and the Tempering Furnace can be Conveyor Type.


Farnalool Iran - Conveyorized tempering furnace for springsThe Leaf and Bars can be loaded to the Hardening Furnace by suitable charger or manually over water cooled rollers. The Hardening Furnace can be Walking Beam Type with minimum number of walking beams depending the length of the Leaf Springs and the Coil Bars to minimize the heat leakages. The Walking and the Fixed Beams are provided with suitable saw teeth and curved teeth to have minimum supporting area for the Leaf Springs and the Coil Bars for better heat treatment during hardening. The walking beam can be Hydraulically or Electro-mechanically operated. The Leaf and Coil Bars can be end-discharged at the opposite end or side-discharged over water cooled Rollers to suit customer’s press for forming Leaf and Coils tailor made to give best results.


The Tempering Furnace can be Conveyor Type and located as per the space available of the customer for suitable tempering.


The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG and Natural Gas singly or a combination of any oil or gas in case of dual fired furnaces.


The Hardening Furnace is provided with Recuperator to improve fuel efficiency, the Recuperator will heat the combustion air up to 200 deg C and the pre-heated air will be supplied to the burners.


The Tempering Furnace can be Directly Heated through Burners located behind stainless steel baffles. The Tempering Furnaces are provided with Recirculation fans for Better Heat Transfer Through Convection and good Temperature Uniformity.


The Hardening Furnace are lined with High Temperature Grade Ceramic Fiber Lining at the side walls and Modules at the roof and door .The bottom hearth of the furnace will be provided with combination of high alumina bricks backed by insulation bricks to minimize the skin temperature.


The Tempering furnace can be of Double Wall construction with inner SS 304 and outer MS or  with Cera board with back up Ceramic Fiber Lining at the side walls roof and door .The bottom hearth of the furnace will be provided with combination of medium grade alumna bricks backed by insulation bricks to minimize the skin temperature.


Additional accessories like, Roller tables at charge and discharge side, Closed Circuit TV Cameras for viewing charge and discharge operations from the control room, On-Line Oxygen Analyzer for flue gas are offered to suit each user’s need.

Ladle And Tundish Pre-Heaters/Driers

Wesman has a full range of Ladle and Tundish Pre-heaters/Driers to offer to Steel Plants. Ladle pre-heaters of both horizontal and vertical type are offered up to a capacity of 250 MT. And Tundish Preheater/Drier of vertical type can be offered  up to a capacity of 60 MT. Vertical ladle/tundish preheater/drier will be used for drying and preheating  of newly relined ladle/tundish. Hot metal ladles are also heated to raise temperature upto 1000-1200 deg.C at desired rate of heating. Vessel pre-heaters with oxy-fuel burners for high temperature preheating are also offered to meet customers requirement.

 

Horizontal ladle preheater/driers mobile or fixed type will be used for preheating steel ladles placed on horizontal stand. For vertical ladle pre-heaters Hydraulically or electro-mechanically operated lifting/swiveling mechanism are offered to meet customer/s requirement. In case of mobile horizontal ladle pre-heaters placed on trolley, electro-mechanical drive unit is provided.

 

Fuel fired Ladle and Tundish Pre-heaters/Driers are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG, Natural Gas and Coke Oven gas singly or a combination of any oil or gas in case of dual fired furnaces.

 

Hood of Ladle Pre-heaters and Tundish Driers are lined with ceramic fibre modules/blankets or with refractory castable with anchors to reduce the heat losses to economic minimum.

 

Wesman has full capability to offer complete control and instrumentation system to suit each customer’s requirement – from simple to very advanced and sophisticated controls. Temperature control loops, fuel ratio control loops, instrumentation for over temperature by stand alone instruments or PLC based SCADA software control systems are offered. Automatic sequential control PLC software is standard with all furnaces.

Aluminum Melting  And Holding Furnace

Emirates Recycling Dubai- Tilting furnace for aluminium meltingWesman has a full range of Aluminium Melting and Holding Furnaces up to a capacity of 20 MT to offer to the aluminium industries for foundry cast house and recycling operation. These furnaces will be reverberatory type tilting or stationary. Furnaces with small dry hearth can be offered for clean automotive scraps. Aluminium scraps are charged through side door with the help of charging machine or manually and after melting, dross removal and fluxing molten metal can also be discharged through tapping spout. Hydraulically operated tilting arrangement is provided to suit the application.


The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG, Natural Gas singly or a combination of any oil or gas in case of dual fired furnaces.


All Wesman furnaces are lined with a combination of alumina bricks backed by insulation bricks to minimize the skin temperature. Furnace bath is lined with phosphate bonded high alumina bricks backed by insulation bricks to ensure durability. Non-wetting type phosphate bonded refractories can be offered for bath lining to prevent seepage of molten metal to the bottom.

Aluminum Coil/Foil Annealing Furnaces

Wesman has a full range of Aluminium Coil/Foil Annealing Furnaces up to a capacity of 80 MT batch to offer to the aluminium industries. These furnaces will be Electrically Heated or Gas Fired and the design will be either Fixed Hearth or Bogie Hearth type to suit customer’s requirement. Aluminium coils/foils placed on the charge carrier can be loaded into the fixed hearth furnace by a hydraulically/electro-mechanically driven charging machine or can be loaded on the bogie with the help of an EOT crane for bogie hearth furnace. After the annealing cycle is completed the foils/coils are discharged from the furnace with the help of discharging machine from the fixed hearth furnace or unloaded from the bogie hearth furnace with the help of the EOT crane.

The foils/coils will be indirectly heated through radiant tube burners located behind stainless steel baffles and are provided with suitable recirculation fans for better heat transfer through convection and good temperature uniformity.

Hot air recirculation inside the furnace is done by efficient axial or centrifugal type recirculation fan, which can be with a two-speed motor or with the VVF drive for low power consumption. Stainless steel baffle for proper hot air circulation inside the furnace is provided. Forced air-cooling arrangement with the help of centrifugal fan can be offered.

The furnace can also be provided with facilities for introducing protective atmosphere like nitrogen gas while carrying out foils/coils annealing.

The furnaces are fired with Wesman’s high efficiency (radiant tube) gas burners which will be suitable for controlled mixing thus providing highly radiant flame, distributing heat release along the entire length of the radiant tube, supported by a full complement of combustion system consisting of combustion fan and gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Gaseous fuel such as LPG or Natural Gas can be used.

For customers preferring electrical heating, the furnace can be provided with electrical heating through vertically suspended heater cartridges located along with the sidewalls of the furnace. The heating elements of the furnace are suitably divided into a number of heating zones with each zone of having their bank of heater cartridges. Each bank heater cartridges shall be connected either in STAR/DELTA or Parallel STAR/DELTA groups to have minimum number of heater cartridges per phase per group so that the heater cartridges of groups can be isolated and replaced without switching off the whole furnace.

The furnaces can be of Double Wall construction with inner SS 304 and outer MS packed in between with Ceramic Fiber Lining at the side walls roof and door to reduce heat losses to economic minimum. The bottom hearth of the furnace will be provided with combination of medium grade alumina bricks backed by insulation bricks to minimize the skin temperature.

For electrically heated furnaces, the process control shall be based on heat head ratio control philosophy with thyristor heater controllers for better temperature control and energy efficiency. Wesman electrically heated furnaces can be offered with 100% thyristor controllers or 30% thyristor with 70% STAR-OFF mode for better energy efficiency during heating & soaking.

Aluminium Homogenizing Furnaces


Wesman has a full range of batch type bogie hearth furnaces up to a capacity of 50 MT and continuous type walking beam furnaces up to a capacity of 10 MT per hour for homogenizing of aluminium extruded billets/logs and slabs.


Jindal Aluminium Bangalore - Double-deck rolldown furnace for aluminium log homogenizingHot air recirculation inside the furnace is done by efficient axial or centrifugal type recirculation fan, which can be with two-speed motor or with VVF drive for low power consumption. Stainless steel baffle for proper hot air circulation inside the furnace is provided. Forced air-cooling arrangement with the help of centrifugal fan can be offered.


The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Light Diesel Oil, LPG, Natural Gas singly or a combination of any oil or gas in case of dual fired furnaces.


As an alternate to fuel fired heating system, the furnace can be provided with electrical heating system through vertically suspended heater cartridges located along with the sidewalls of the furnace. The heating elements of the furnace are suitably divided into number of heating zones with each zone of having their bank of heater cartridges. Each bank heater cartridges shall be connected either in STAR/DELTA or Parallel STAR/DELTA groups to have minimum number of heater cartridges per phase per group so that the heater cartridges of groups can be isolated, without switching off the furnace in case they need replacement.


To improve the fuel efficiency, Recuperators for heating combustion air upto 200°C is provided for fuel fired continuous walking beam furnaces.


Wesman Homogenizing furnaces are lined with a combination of ceramic fibre board backed-up by ceramic fibre blankets of suitable grade with stainless steel studs for side wall, roof and doors to minimize the skin temperature. The hearth is lined with refractory bricks backed-up by insulation bricks, specially designed to withstand load. In an alternate design, the furnace can also be made of double wall construction with inner stainless steel (AISI-304) and outer mild steel for side wall, roof and doors in place of ceramic fibre board backed-up by ceramic fibre lining.


For electrically heated furnace, the process control shall be based on heat head ratio control philosophy with thyristor heater controllers for better temperature control and energy efficiency. Wesman’s electrically heated furnaces can be offered with 100% thyristor controllers or 30% thyristor with 70% STAR-OFF mode for better energy efficiency during heating & soaking.

Wesman has a full range of Soaking Pits for Aluminum Slabs up to a capacity of 100 MT to offer to the aluminium industries. These furnaces will be Electrically Heated. Slabs are loaded into the pit with the help of an overhead crane. After heating and soaking, aluminium slabs are discharged from the pit one by one for rolling operation. The Pit will be essentially a single open top box with a working chamber and heating chambers separated by dividing baffle wall. The work chamber will hold the aluminium slabs stacked horizontally separated by spacers for processing.

 

Hot air recirculation inside the pit is done by efficient axial flow recirculation fan, which can be with two-speed motor or with VVF drive for low power consumption. Stainless steel baffle for proper hot air circulation inside the furnace is provided.

 

The furnace is provided with electrical heating system through vertically suspended heater cartriges located along with the sidewalls of the furnace. The heating elements of the furnace are suitably divided into number of heating zones with each zone of having their bank of heater cartriges. Each bank heater cartridges shall be connected either in STAR/DELTA or Parallel STAR/DELTA groups to have minimum number of heater cartridges per phase per group so that the heater cartridges of groups can be isolated, without switching of the furnace to ensure easy replacement.

 

The furnaces can be of Double Wall construction with inner SS 304 and outer MS packed in between with Ceramic Fiber Lining at the side walls & roof to reduce heat losses to economic minimum. Hearth inside the pit will have single plate construction duly insulated with High Alumina Firebricks backed by Cold Face insulation bricks to minimize the skin temperature.

Solution Heat Treatment Furnace For Aluminium

Wesman has a full range of Solution Heat Treatment Furnaces of batch capacity up to 25 MT for heat treatment of Aluminum and Alloy components for Aluminum Industries like Auto components, Cylinder Heads, Pistons, Aluminum Sheet, Aluminium Ingots, Conductors, and Aluminium Foils etc.


The Solution Heat Treatment furnaces are drop bottom type with the furnace supported on a elevated structure with the water quenching tank underneath to ensure quick quenching after desired heating as per the specific heat treatment cycle of solution treatment.


These furnaces are of Circular/ Rectangular construction with insulated cover that hydraulically/electro-mechanically move side ways to ensure charging of Circular/ Rectangular workbasket from the loading platform through suspended wire-rope type hydraulically/electro-mechanically operated lifting and lowering mechanism. The loading platform and the quenching tank are mounted on a hydraulically/electro-mechanically driven trolley above the ground level to facilitate quicker quenching (within 30secs), where in the trolley will move underneath the furnace with loading platform under the furnace for loading the charge material into the furnace by the lifting and lowering mechanism for desired heating and soaking. Subsequently the quenching tank will move under the furnace for quenching after the desired heating and soaking. In case the permissible quenching time is little longer i.e. beyond 45 secs the furnace can also be offered with a cemented quenching tank below ground level with loading platform mounted on a trolley moving above the quench tank for desired loading and unloading.


These furnaces can be either electrically heated or fuel fired The electrically heated furnaces are provided with resistive Strip/Wire heating elements located on the sidewall of the furnace. The heating elements of the furnace are suitably divided into number of heating zones and can be controlled through Contactor or Thyrister based control philosophy through PID controllers. Fuel fired furnaces are offered with Wesman’s high efficiency radiant tube burners for Oil/Gas application supported by a full complement of combustion system with safety devices.


Hot air circulation inside the furnace is made by efficient centrifugal or axial type recirculation fan, which can be with two-speed motor or with VVFD drive. The furnaces are of double wall construction with ceramic fiber blankets sandwiched between inner and outer wall for optimum insulation and minimum wall losses.


Wesman has full capability to offer complete control and instrumentation system through PLC based or Hardware based logic controls.

Wesman has built a large number of fuel fired and electrically heated Bogie/Fixed/Continuous ovens for the past five decades. Wesman has a full range of Bogie/Fixed/Continuous ovens up to a capacity of 500 MT to offer to Foundry Cast House,  Heavy Engineering, Automobile, Rail Wagon, Electrical Machines and other metal industries with temperature range of 50 deg C to 450 deg C.  The fixed/bogie hearth ovens can be offered with single or double doors applications however the Continuous ovens are always with double door application for one end charging and other end discharging. The material are loaded on the bogie hearth ovens with the help of EOT crane or any mechanical device on the electro-mechanically operated bogie and by charging machine or Air casters in case of fixed hearth ovens for the desired drying and curing.

 

The continuous ovens can be conveyorised or trolley type, the Conveyor of Conveyorised oven will be electro mechanically operated and the pusher for the trolley of the trolley type oven can be either electro mechanically or hydraulically operated. In continuous ovens material is loaded at the front end of the conveyor/trolley and unloaded at the back end of the oven after maintaining the desired retention time for satisfactory drying/curing.

 

The ovens can be Fuel fired or electrically heated, In case of fuel fired ovens are fired with Wesman’s high efficiency burners supported by a full complement of combustion system with safety arrangements.

 

In case of electrically heated ovens with electrical heating system through resistive Cartridge type/Tubular type heating elements located along with the side/back walls/roof of the oven. The heating elements of the oven shall be divided into suitable no of zones as per the size of the oven and will be control by PID based control philosophy with Thyrister/Contactor based relay logic.

 

Generally, Wesman Bogie/Fixed/Continuous ovens are lined with Mineral Wool/Ceramic fiber blankets packed in between double wall panels on the side wall, roof and door and hearth of the ovens to minimize the skin temperature. The inner wall of the oven can be of Mild Steel or Stainless steel depending upon the service temperature.

 

The Ovens are provided with suitable baffles with recirculation fans for better heat transfer due to convection and good temperature uniformity. The baffles and recirculation fans can be made out of Mild Steel or Stainless steel depending upon the service temperature. The drive motor of the recirculation fans is VVFD driven for soft starting and better temperature controls.

Fuel Fired Cremator Furnace

India has the world’s largest population adopting the cremation method for funerals. The traditional method is by wooden pyre and in larger towns and cities by electric cremator furnaces.

Due to ecological reasons, the wooden pyre method will gradually phase out. The current technology level which depends on Electric Cremator furnace has many shortcomings, mainly relating to capital cost, cost of operation, compliance with pollution norms etc. For a more detailed comparison of electric furnace with Oil and Gas fired furnace, please see attached write-up.

In the near future, fuel fired Cremators will become the preferred route for cremations, as in the rest of the world, because of its many advantages.


Salient Features

The Wesman – Furnace Construction “Joule” Cremator Furnace is manufactured to the design of our collaborator M/s. Furnace Construction Company Ltd., U.K. and is designed to comply with the current pollution norms of U.K. and other advanced countries, more stringent than current “Indian Pollution Norms” with proven economical operation, long life with low maintenance cost. Furnace Construction has the largest share of the cremator market in the U.K. and have over 350 installations worldwide.

The “Joule” Cremator comprises a unique patented secondary combustion system, built inside a high quality ceramic fiber lined enclosure, surmounting the main or primary combustion chamber. The whole cremator is encased in a rigid steel casing mounted on legs to raise the cremator above floor level and provide ground level ventilation to the Furnace Room floor slab.

The cremator is provided with automatically clamped charge and rake doors to ensure tight sealing during operation. This eliminates the problem of ‘foul smell’ during the cremation process.

The “Joule” cremator incorporates several unique safety features including a patented atomized water mist injector which retards body ignition until the charge door is lowered, thus protecting the Operator from the dangers of “flash-back” on charging and totally eliminating the release of fumes into the furnace room.

The “Joule” cremators are more flexible in their control system, recognizing and responding to a much wider range of operating condition. The system automatically pre-heats the cremator and once charged, will automatically compensate for size and type of body with the help of pre-set timer.

On start up, the charge door is inhibited until the correct temperature has been achieved. Once the cremator is loaded, the door will again be inhibited thus preventing accidental operation.

The quantity of primary and secondary air will be constantly regulated to match the requirements at all stages of operations i.e., when

The body with carrier is charged and

The body becomes the primary source of combustion.

The “Joule” cremator is provided with automatic temperature controlling instruments for both primary and secondary chambers with other safety devices.

Combustion products exit the main chamber through a slot in the rear of the roof, separating the main and secondary zones. The products are mixed with secondary air supplied through a swirler and through the flame of the secondary burner into secondary chamber. The secondary burner modulates and for the major part of the process will be on low fire. The high intensity combustion tube ensures that the products are thoroughly mixed with air and totally burned. The products then exit the tube into a ceramic fiber lined enclosure which being maintained at about 8500C, provides the extra volume required to achieve the designated retention time, which is two seconds as per U.K. norms.

Charging And Discharging Machine For Coil/Foil Annealing Furnaces.

Wesman offers Charging/Discharging machines for loading and unloading of the Foils/Coils along with the Charge Rack into Fixed hearth chamber furnaces for desired Coil/Foil Annealing. The Charging/Discharging machines can be common for various furnaces. The Charging/Discharging machines will have fork arms, which can move forward backward, up and down and move side ways. These machines can also be designed to rotate 180/360 Deg.  The forward and back ward movement of fork arm on rollers will ensure movement of Coils/Foils into the furnace, the down ward and up ward movement will ensure proper positioning/pick up of Foils/Coils along with the Charge Rack on furnace hearth during loading and unloading. The rotation of the machine by 180/360 deg facilitates picking/keeping the Coils/Foils from the charging station located in front of the furnace. The charging machine can also move side ways on rails to facilitate to load into multiple furnaces.

The forward backward, up and down, and side ways movement can be electro-mechanically or hydraulically operated .The side ways movement in case of long span on rail and rotating movement will be only electro-mechanically operated.

The complete sequential operation of the Charging/Discharging machines are inter-locked with the heating profile of foil/coil annealing furnace through PLC or Relay based logic system.


Charging And Discharging Machine For Rotary Hearth  Furnaces

Wesman offers machines of identical type, one meant for charging and the other for discharging of Billets one at a time. These machines shall work in synchronization with the movement of the hearth following a particular sequence. Necessary interlocks will be provided in the electrical control system to ensure safety during the sequence of operation. The machine will have internally water cooled arms and a pair of tongs to grip the material. For lifting and lowering, for grabbing and releasing of Billets by the tongs, hydraulic cylinders shall be provided. For forward and backward (reverse) movement of the arms, hydraulic motors shall be provided.

Both charging & discharging machines will travel between fixed points of pick-ups or dropping/lowering. Provision will be kept for manual withdrawal of the machine arms out of the furnace in case of power failure.


Charging And Discharging Machine For Tray Pusher Type Heat Treatment  Furnaces

Wesman offers machines of identical type, one meant for picking the charge trays from the hardening furnace after desired heat treatment and transferring the same to the quenching tank for quenching and the other for taking out the charge trays from the tempering furnace after tempering cycle and transferring the same to the cooling tank and subsequently to the unloading station of  one  tray at a time. These machines shall work in synchronization with the movement of the trays inside the hardening and the tempering furnace as per desired heating cycle following a particular sequence. Necessary interlocks will be provided in the electrical control system to ensure safety during the sequence of operation. The machine will have fork arms to pick up the charge trays . For lifting and lowering and for forward and back ward movement of trays can be hydraulically/electro-mechanically operated.

Both charging & discharging machines will travel between fixed points of pick-ups or dropping/lowering. Provision will be kept for manual withdrawal of the machine arms out of the furnace in case of power failure.

Optimum Zone Setpoint Calculation Software

Wesman, jointly with a USA based software developer has developed an off-line software to manage optimum heating strategy for Walking Beam, Pusher, Rotary Hearth Furnaces used in Steel Reheating and Forging Applications. Use of this easy to use powerful 'intelligent' tool will save the end user enormous energy costs by giving the optimum setpoints for the furnace zones improving the overall thermal and metallurgical performance of the continuous furnace in normal operation as well during unforeseen delays or interruptions that occur in continuous mill operations in steel plants while processing any size, shape and grades of products in a continuous furnace.

Key Feature:

Recipe/Set-point Management (determination of optimum zone temperatures during constant production)

The system offers the ability to create setpoint recipes (zone setpoint temperatures) for various grades and shapes of product at different Production Rates or Push/Walk Rates

Delay Set-point Management (determination of optimum zone temperatures during delays)

The system offers the ability to create setpoints (zone setpoint temperatures) for various grades and shapes of steel/Aluminum at different delay time. The system can handle both Scheduled and Unscheduled delays.

The software can also communicate to the Level 1 furnace control system for downloading optimum setpoints

The software also comes with the following additional features:

• Furnace can be configured with Zone/Furnace Dimensions, Furnace Insulation, Burner Type, Fuel etc.
• Charges can be configured from basic shapes (Billets, Ingots, Slabs, and Rounds) by entering dimensions and material properties(provided with the software).
• Property Data: Comes with entire database of Steel Grades, Fuel types, and Refractory materials.
• Provides capability to create new Steel Grades, Refractory materials and Fuel types

Results include:

• Charge Temperature profile during reheating and at exit
• 2 D temperature of the charge at any furnace location for Slab Heating furnace with Skids
• Scaling/Decarburization depth at any point during the heating cycle
• Zone wise thermal loading, fuel and air inputs
• Heat Audit/Energy Consumption Calculations: The software comes with a tool to perform Heat Audit allowing user  to perform calculations to determine fuel consumption, furnace efficiency, and cost of running a furnace.
• Calculates heat to part, refractory loss, heat to gases, and heat and energy/power consumed in different zones,
• Heat loss through the flue, fuel consumption and furnace efficiency. The results are displayed on a Sankey diagram
• Results from each calculation can be displayed in a report format. The results can be directly printed, saved as a PDF format or Excel spread sheet

Wesman has a full range of Cylinders Heat Treatment Furnaces up to a capacity of 60 cylinders per hour or 10 MTPH to offer to Cylinders Manufacturing industries. Heat Treatment line comprises Hardening and Tempering Furnaces with Quenching Facilities. The hardening furnaces can be walking beam type with quenching system for polymer or oil as per process requirement and tempering furnaces can be walking beam or conveyor type.

Cylinders can be manually placed on a charging conveyor in front of walking beam hardening furnace. Walking beams of hardening furnace will pick-up the cylinders from the conveyor and will move inside the hardening furnace at required spacing from charging to discharging end. The heated cylinders will be discharged out of the hardening furnace one by one and will be placed over the cradle of the hydraulically operated vertical or rotary type quenching system which will immerse the cylinders into the quenching oil. After the quenching cycle is over, the cradle will lift-up from the quenching tank and the cylinders will be moved forward to charge side of the tempering furnace by means of electro-mechanical discharge conveyor.

Cylinders one by one will again will be charged on the hearth of walking beam/conveyor type tempering furnace at required spacing and will be moved from charging end to the discharging end by means of hydraulically operated walking beams or electro-mechanically operated conveyor system. After the tempering process, cylinders one by one will be discharged at the opposite end of the tempering furnace and will move to unloading area where the cylinders can be unloaded by means of hoist or manually.

The furnaces are fired with Wesman’s high efficiency burners supported by a full complement of combustion system consisting of combustion fan, atomizing fan, oil heating and pumping systems and/or gas trains. In addition auto ignition, flame failure safety and complete control systems are offered. Practically any type of liquid or gaseous fuel can be used viz. Furnace Oil, Light Diesel Oil, LPG and Natural Gas singly or a combination of any oil or gas in case of dual fired furnaces.

The Hardening Furnace is provided with Recuperator to improve fuel efficiency, the Recuperator will heat the combustion air up to 200 deg C and the pre-heated air will be supplied to the burners.

The Tempering Furnaces can be directly heated through Burners located behind stainless steel baffles. To allow uniform heating inside the tempering furnace and ensure sufficient circulation of hot air, suitably sized recirculation fan assembly will be provided. Baffles fabricated from stainless steel sheets of AISI-304 are installed to guide the recirculation of hot gas inside the furnace. These baffles are suitably anchored with heat resistant studs from sidewalls and roof.

The Hardening Furnaces are lined with high temperature grade ceramic fiber lining at the sidewalls and modules at the roof and door. The bottom hearth of the furnace is provided with combination of high alumina bricks backed by insulation bricks to minimize the skin temperature.

The Tempering furnaces can be of Double Wall construction with inner SS 304 and outer MS or with Cera board with back up ceramic fiber lining at the sidewalls roof and door. The bottom hearth of the furnace will be provided with combination of medium grade alumna bricks backed by insulation bricks to minimize the skin temperature.

Wesman has full capability to offer complete control and instrumentation system to suit each customer’s requirement – from simple to very advanced and sophisticated controls. Temperature control loops, furnace pressure control loops, fuel ratio control loops, instrumentation for over temperature and recuperator safety by stand alone instruments or PLC based SCADA software control systems are offered.

Wesman has a full range of monorail conveyorised furnace for tempering and drying upto 50 MTPH to offer to Foundry Cast House, Forgings and other metal industries. The furnace comprises of number of hot air generators installed below the hearth with hot air recirculating fans, baffles, overhead monorail conveyor for movement of charge material from charging to discharging end of furnace.

 

Material, one by one, will be loaded at the charge end of the furnace over a steel hook attached to overhead trolley riding on monorail conveyor. Indexing of trolley with hook will be hydraulically operated for movement from charge to discharge end. The hooks will travel through the furnace as per indexed trolley pitch and material will be unloaded one by one manually or by a suitable unloading mechanism at the discharge end. Return monorail conveyor will move the empty trolley-hook assembly from discharging to the charging end for the purpose of loading.

 

The furnaces are oil/gas fired with Wesman’s high efficiency burners located at one end of hot air generators supported by a full complement of combustion system with safety devices. The Furnaces are provided with suitable stainless steel Baffle with Recirculating fans for Better Heat Transfer through Convection and close Temperature Uniformity.

 

The furnace is of Double Wall construction with inner SS 304 and outer MS with back up Ceramic Fiber Lining at the side walls roof and door. The bottom hearth of the furnace and hot air generator chambers are lined with combination of medium grade alumina bricks backed by insulation bricks to minimize heat losses and to reduce the skin temperature.

 

Wesman offers complete control and instrumentation system to suit each customer’s requirement – from simple to very advanced and sophisticated controls. Temperature control loops, fuel ratio control loops, and instrumentation for over temperature by stand alone instruments or PLC based SCADA software control systems are available.

We are engaged in offering Furnace Proposal Questionnaire for our clients.


For more detail click on pdf.