EOW May 2014

News Technology

Aluminium drawing with Vicafil TFH 1167

ratio is set exactly within a specified range. The high control precision and stability of the gas/air ratio makes the new furnaces superior to pre mix systems. In addition to the savings on energy, controlling the air/ gas ratio keeps NOx emissions low and prevents decarburisation of the wire. The furnace temperature is adjusted with a precision of ± 2°C. A central recuperator installed in the waste gas duct preheats the combustion air for the high-speed burners to 200-250°C, while reducing the waste gas temperature at the stack from 600°C to 400-500°C. Already in the preheating zone Wire Körner exploits the thermal energy of the waste gas to heat up the wire entering the furnace. This reduces the energy demand for preheating. In contrast to previously used burners, the high-speed burners employed by Wire Körner can be adjusted in several steps. This ensures that the burners consume exactly the amount of energy they need, not more. The company has brought down heat losses via the furnace wall by optimising the layout of the wall, by insulating ceramic fibres. An additional coating ensures a long service life of the furnace wall even under conditions of high CO contents and high flow velocities. An additional, 2.5-cm-thick Microtherm® insulating layer behind the refractory brick lining brings down heat losses even further. The furnace is directly heated. The heat is transferred into the wire by convection, at flow velocities of up to 120m/s. This provides much better energy efficiency than heating by radiation. No additives are required during the whole product life. Using Vicafil TFH 1167 affords reduced bath maintenance costs, and thanks to its properties, it suits most drawing operations and diameters from 0.8mm to rod break drawn. Moreover, it can be used in either immersed or sprayed type drawing machines, without damaging equipment. Condat – France Website : www.condat.fr improve cooling but reduce consumption by minimising the amount of residue on drawn wire • includes a package of additives to limit the production of sludge, thus reducing machine maintenance and extending lubricant life.

Offering high efficiency and economic lubricants has always been a great challenge for wire drawing lubricant manufacturers. French company Condat answers this problem with its widely approved aluminium and aluminium alloy drawing oil, Vicafil TFH 1167, which was launched at wire 2014 in Düsseldorf, Germany, in April. This oil-based lubricant was developed with a primary objective of providing the best performance to preserve dies and draw high quality wires; but without compromising simplicity of use and long service life. Vicafil TFH 1167: • uses a low viscosity base oil in order to

▲ ▲ Aluminium drawing oil Vicafil TFH 1167 from Condat New series of directly heated furnaces

Wire Körner has launched a new series of directly heated patenting furnaces fitted with automatic furnace atmosphere control and burner with heat recuperation. With these new energy-saving furnaces, the company is further expanding its range of efficient and eco-friendly heat treatment plants for wire. Based on his good experience with the furnace, a German customer has already ordered an extension to his existing unit. The first unit of this new furnace generation has been in operation for two years. Designed for a throughput of 2,000t per hour, it processes wire in diameters from 1.5 to 5.5mm. The plant expansion was expected to be commissioned in April 2014. By implementing a wide array of innovative features, Wire Körner has increased the efficiency of patenting Quality offensive continues

furnaces for wire and achieved savings on energy consumption of some eight to ten per cent compared to conventional furnaces. The very first furnace of this new generation has already been in production for more than two years. With an innovative sensor, Wire Körner has realised a system for controlling the furnace atmosphere. Via the furnace control system the air/combustion gas ▲ ▲ Wire Körner is expanding its range of furnaces

Sikora continues its product offensive for quality assurance in drawing towers with the new fibre lump 6003 micro. This sets a quality statement in the fast growing fibre market. The new lump detector detects faults on the fibre surface 100 per cent continuously during the drawing process at a speed of up to 3,000m/min. This performance is achieved by the use of six measuring axes. Shadow areas are eliminated and even the smallest

▲ ▲ The new fibre lump 6003 micro from Sikora

faults of a height from 5µm are detected. The length of detectable faults is 50µm. In combination with a double sensor technology, punctual non-conformities are detected. The fibre lump 6003 micro is designed for product diameters from 100 to 500µm. The device can easily be integrated into new or existing drawing towers, and can be connected to both the Sikora display and control system fibre ecocontrol or to a line computer. In addition to the installation in drawing towers, the fibre lump 6003 micro is suitable for colouring lines. Sikora AG – Germany Website : www.sikora.net

Wire Körner GmbH – Germany Website : www.wirekoerner.com

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May 2014