HPH®
HIGH PERFORMANCE HYDROGEN
HPH® Bell-type Annealing Plants and Processes
for the Heat Treatment of Rod and Wire
TENOVA. INNOVATIVE SOLUTIONS FOR METALS AND MINING
TENOVA
LOI THERMPROCESS
Tenova LOI Thermprocess is your global partner in the world of industrial furnace
technology. Our clients appreciate our know-how and experience backed by
hundreds of references and a history of over 100 years in the furnace sector.
We offer highly advanced process technologies, high reliability, high-quality products
and services, and a wide range of custom-tailored solutions for reheating and
heat treatment plants for the metal industry.
Especially for the soft annealing, recrystallizing and spheroidizing of wire coils, our
portfolio incorporates HPH® Bell-type Annealing Furnace Plants for batch operation,
as well as continuous and semi-continuous Roller Hearth Furnace Plants.
Tenova LOI Thermprocess is a member of the Tenova Group, leveraging a total
staff of more than 2,500 forward-thinking employees located in 19 countries across
5 continents. Tenova works alongside clients to design and develop innovative
technologies and services that help mining and metal companies to reduce costs,
save energy, limit environmental impact and improve working conditions for their
employees.
3
Tenova Companies for Heat Treatment Processes
and Plants for Rod and Wire:
Chamber Furnaces u
for solution annealing
with all kinds of
quenching technologies
Semi-continuous
Heat Treatment Plants
Walking Beam and Pusher
type Reheating Plants
HPH® Bell-type Annealing u
Plants (batch type)
Rotary-type Furnaces
for solution annealing
with all kinds of quenching
technologies
� RollerHearth Annealing
Plants (continuous type)
LOI EXPERTISE FOR BELL-TYPE
ANNEALING PLANTS
Tenova LOI Thermprocess, including the activities of its predecessors Matthias
Ludwig and Nassheuer, has been a technological market leader in Bell-type
Annealing Furnaces for more than 70 years. Throughout the world, more than
8,500 LOI annealing bases have been installed. About 5,000 operate with an
HNx controlled atmosphere. More than 3,500 bases use HPH® annealing
technology with pure hydrogen.
Tenova LOI Thermprocess is therefore also a market leader in the field of high
performance hydrogen annealing plants for steel strip and steel wire.
5
R&D AND PROCESS TECHNOLOGY MAXIMUM ENERGY EFFICIENCY OPTIMUM PROCESS RELIABILITY
Tenova LOI Thermprocess has is ensured by features including “Zero Defect” philosophy
comprehensive expertise in HPH® • Individual heat exchangers for
Bell-type Annealing technology and is each burner of the heating hood DESIGN FEATURES:
continuously developing this expertise • HPH® High-convection heat • Seal components installed only on
through R&D and practical tests. transfer the base
• Atmosphere gas supply systems
ATMOSPHERE GAS COSTS with redundant sensors for safety
HIGHLY EFFICIENT SPACE are minimized by selecting the best purposes and redundant valves
UTILIZATION atmosphere gas for the process, e.g. on the valve stand
is ensured by different charging • Nitrogen for spheroidizing hot
possibilities. rolled wire PROCESS FEATURES:
• Useful diameter: • Hydrogen for recrystallizing • Automatic adaptation of annealing
1,500 – 4,600 mm drawn wire atmosphere purging to the
• Useful height: annealing process selected
1,500 – 5,400 mm • Sophisticated process control
• Charge weight: system including plausibility
up to 90 t checks, malfunction logging and
• Coil diameter: automatic safety responses
300 – 1,500 mm
t HPH® Bell-type Annealing Plant for wire coils
with the largest usable dimensions in the world
HPH® FURNACE FEATURES
• Tenova LOI Thermprocess market share over the past
10 years approx. 50 %
• Both multi-stack and single-stack plants available
• Plants with recirculation up to material temperature
of 900 °C
• Hot-rolled or drawn wire coils can be treated.
The materials treated include:
• Mild steels
• Chain and spring steels
• Unalloyed and alloyed steel grades
(CHQ and ball bearing steel)
• Tool and high-speed steels (HSS)
• High-alloyed stainless steels
• Non-ferrous metals
• The annealing processes available include soft annealing,
recrystallizing and spheroidizing without decarburization
or oxidation
• In N2, HNx or 100 % H2 atmosphere
• Dew point below -60 °C
• Reliable reproducibility of high-quality annealing results
with regard to uniform mechanical and metallurgical
properties ensuring excellent cold working conditions � HPH® Bell-type Annealing Plant for CHQ wire
6
BEST QUALITY WIRE HIGH PROCESS RELIABILITY The annealing time required for
Annealed wire of the highest quality Tenova LOI Thermprocess Bell- the spheroidizing of rolled wire is
can only be produced with an type Annealing Plants for steel determined mainly by metallurgical
extremely clean controlled atmosphere. wire are equipped for HPH® (High factors. It is recommended to use a
At Tenova LOI Thermprocess the Performance Hydrogen) technology. controlled atmosphere of nitrogen.
base plate of the annealing base is They can be operated either with For recrystallizing drawn wire,
designed to provide a fully gas-tight a controlled atmosphere of nitrogen which has a layer of grease on its
seal between the annealing space (or HNx gas) or with pure hydrogen. surface, hydrogen is used as the
and the surrounding air. Controlled
atmosphere dew points of -60 °C
and better can be reached.
Heating hood with heat exchangers u
for high heating efficiency
� Microstructure of wire
in hot-rolled condition
t Hydraulic or pneumatic clamping
7
controlled atmosphere. The grease Hydrogen and nitrogen can be mixed u
evaporates and reacts with the in any proportions (0 -100 %) with
the Tenova LOI Thermprocess
hydrogen, ensuring a clean surface. valve stand
The high heat transfer rate possible
with hydrogen also contributes
to excellent annealing results with
minimum annealing times.
Cooling hood with Jet cooling u
for high cooling efficiency
� Spherodising for
stress relieving/
lowest tensile strengths/
best elongation properties
t Gas tight, water cooled, base recirculation
motor, variable frequency controlled, up to 55 kW
8
TYPICAL CHARGE ARRANGEMENTS
� Annealing of non-ferrous � Flat wire annealing � Charging of spools of � Single-stack arrangement of
wire coils drawn wire wire coils
Rod annealing
9
TYPICAL PLANT TYPES
Coil outer diameter No. of Inner cover diameter Plant type
(~ d in mm) stacks (mm) (~ D)
1000 1 1800 160
4 2950 260
7 3600 320
1200 1 1800 160
3 2950 260
4 3600 320
7 4700 420
1300 1 1800 160
d 4 d 3600 d 320
7 4700 420
D D D
D = 2.154 x d D = 2.414 x d D=3xd
BASES DESIGNED FOR A LONG SERVICE LIFE
Tenova LOI Thermprocess bases are extremely sturdy • Tried and tested annealing base design
and are designed for a virtually unlimited service life as • High recirculation rate for high annealing capacity
well as very easy cleaning and maintenance: and best temperature uniformity
• Unique design of recirculation motor and impeller
• Strategies for ensuring a very clean wire surface
� Annealing base for nitrogen and hydrogen annealing � Base designed with FEM strength modelling, equipped
with honeycomb grating and set of confusor/ diffusor with fixed charging stations for extremely high stability
parts made from heat-resistant material
10
HPH® HEATING HOOD
The heating hood may be heated
either by burners or by an electric
system. Burners for natural gas (high
and low calorific value), coke oven
gas and light fuel oil are available.
High-grade insulation minimizes heat
losses at the same time as ensuring
highly homogeneous temperatures
over the entire height of the stack.
A hydrogen atmosphere combined
� Electrical heating with different zones, � Tangential layout with 12 burners in three with high-performance recirculation
thyristor or on/off-controlled different levels. Each burner has a capacity systems makes for rapid heat transfer
of 150 kW; one burner for H2 and lubricant
residues after burning. All are equipped to the charge, allowing high heat
with individual heat exchangers. input values and burner ratings.
The short annealing times which
are possible mean that energy
consumption is reduced to a minimum.
With advanced burners and highly
effective on-off control and process
firing systems, HPH® plants reliably
comply with applicable emission
limits throughout the annealing
cycle. Emissions are significantly
below the limits.
t HPH® Heating hood
placed over the inner
cover with baffle inside
11
HPH® JET COOLING HOOD JET COOLING ADVANTAGES
Bell-type Annealing Plants for the • Relatively low capital cost
heat treatment of steel wire coils • No cooling water required
mainly use Jet cooling. This type of • Optimized nozzle configuration,
cooling system is especially well ensuring homogeneous cooling
suited for plants with long annealing of all coils
times (e.g. spheroidizing or high- • Low noise output
temperature processes.) • 10 % capacity increase for
existing plants
The Jet cooling hood developed • Energy savings compared to
by Tenova LOI Thermprocess is conventional cooling hoods
patented (EP 0894150, US
6177044). Cooling is provided On the basis of its extensive plant � Jet cooling with computer-optimized
by air jets targeted directly at the and process expertise, Tenova LOI nozzle design results in 20 % higher
cooling capacity.
outside of the inner cover. These Thermprocess can offer the ideal
jets are generated by a large number cooling system for any application:
of air nozzles installed on the steel • High-performance air cooling
casing of the Jet cooling hood. For (Jet cooling)
highly effective cooling, nozzles of • Conventional air cooling
different diameters are distributed • Water spray cooling
over the height of the cooling hood. (air/water)
In addition, the top of the hood has
a large number of air nozzles for
intensive cooling in this area.
Two or three radial-flow fans extract
air from the cooling hood. Compared
with a parallel-flow air cooling hood,
heat transfer with a Jet cooling hood
is three times more intensive.
Jet cooling hoods are an
attractive alternative for improving
the performance of existing
Bell-type Annealing Plants.
Jet cooling hood u
for optimum
cooling results
CONTROLS FOR FURNACES AND
THERMAL PROCESSES
Fully automated processes are indispensable
for achieving constantly high process quality
combined with reliable, economical
series production.
13
CONTROLS FOR FURNACES Tenova LOI Thermprocess offers • Comprehensive expertise in
AND THERMAL PROCESSES control systems including all the process electronics, control
Modern control systems ensure: hardware and software required system engineering and automation
• High safety levels from the switchgear assembly to the • Switchgear assemblies,
• Optimized processes supervisory control system. ProView® components
• Constant, high product quality control systems are based on a • Automation
• High plant availability modern application development • ProView® supervisory system
• High productivity system designed for the latest • Throughput and material flow
• Optimum conditions for operation Windows operating systems. optimization
and maintenance Mobile versions (ProView® Mobile)
• Minimal energy and utility are available for use with the latest
consumption mobile phones and tablet systems.
• Lower pollutant emissions � ProView® Mobile supervisory system
SERVICE AND SPARE PARTS
Our dedicated service system makes the full know-how of Tenova LOI
Thermprocess, which has been gathered over the decades and is still
being developed, available to our customers at all times. The worldwide
representation of Tenova means that our customers have direct access
to our specialists for spare parts and services, as well as modernization,
retrofit and relocation projects, all tailored to their specific needs.
MODERNIZATION, RETROFIT & SERVICES SPARE PARTS
RELOCATION We provide our customers with The technical service personnel
In cooperation with our qualified tailor-made maintenance programs, of Tenova LOI Thermprocess is
personnel, our customers are able to regular technological updates, well prepared to supply the right
find the ideal optimizations for their operation assessment and personnel spare parts within the shortest time.
equipment. Our specialized service training with the aim of keeping their Individual parts are available for
solutions allow customers to operate equipment running at full capacity delivery within 24 hours.
their equipment at the highest possible in line with best practices, avoiding
productivity and efficiency levels at unforeseen delays and unplanned
the same time as focusing on safety interventions.
and sustainable development.
15
MAINTENANCE & REPAIR MODEM & PHONE SERVICE CONSULTANCY
Our experts are available for Control systems and connected Our process engineers and our
maintenance work on systems plants can also be inspected commissioning and control systems
including: online by remote maintenance. specialists are available to provide
• Mechanical furnace systems This approach allows any problems innovative and reliable advice and
• Electrical furnace systems to be reliably identified and support to our customers in line with
• Refractory linings eliminated and new program their requirements.
• Burner systems tools and software updates to
• Heating systems be uploaded immediately to our
• Cooling systems customers' systems.
• Control systems
• Automation
• Mathematical models
INDUSTRY 4.0 shortened.
Tenova LOI Thermprocess 4.0 offers:
• Production data exchange with higher-level
ERP / MES systems
• Production data recording and analysis at any time
during and after the process
• Process and throughput optimization
• Alarm management via app / e-mail / SMS
• Mobile input of production or
measuring data
Integrable Certification System
As the mobile alarm management (MAM) can be
implemented on various Theplatforms,
automated theevaluation
alarms of SAT and
are available at any place and time.
TUS is part This
allows reaction times to
of be
theshortened.
integrable certification system.
• Data input on the spot via a mobile
Touch Panel
Integrable Certification System for CQI-9-systems • Import of TUS-measuring data and
their evaluation
The automated evaluation of SAT (System Accuracy Tests) • Permanent storage of measuring data
and TUS (Temperature Uniformity Surveys) is part • Memory management for the next tests
of the integrable certification system. • CQI-9 goes mobile
• On-site data input mobile Touch Panel
• Import and evaluation of TUS measured data As the Mobile Alarm-Management MAM
• Permanent storage of measuring data can
• Memory management for the next tests be implemented on various platforms, the
alarms
are available everywhere and at all times.
As a consequence reaction times can be
LOI Thermprocess GmbH Tenova LOI Thermprocess –
Schifferstrasse 80 Moscow
47059 Duisburg Tenova East Europe, LLC
Germany Ul. Gruzinskij val,
T +49 203 80398-900 dom 10, stroenie 4
F +49 203 80398-901 123557 Moscow
loi@[Link] Russian Federation
T +7 495 995 95 08
F +7 495 995 95 08-619
loi-moscow@[Link]
Tenova LOI Thermprocess – Tenova LOI Thermprocess –
Poland India
LOI Poland Sp. z o.o. Tenova India Pvt. Ltd.
ul. Zagórska 79 A Wing, 5th Floor
Tarnowskie Góry iThink Techno Campus
42-680 - Poland Pokhran Road No. 2
T +48 32 284 1639 Thane (West)
F +48 32 284 2223 Thane, Maharashtra 400601
loi@[Link] India
T +91 22 6248 9700
[Link]@[Link]
Tenova LOI Thermprocess – Tenova LOI Thermprocess –
Tianjin US
Tenova Technologies Tenova Inc.
(Tianjin) Co., Ltd. Cherrington Corporate Center -
2nd Floor - Tower B, Corporate Center Drive 100
Keyuan Keji Coraopolis
Development Centre No. 8, PA 15108-3185 - United States
Keyuan East Road Tianjin T +1 412 262 2240
Hi-Tech Industry Park F +1 412 262 2055
Tianjin, 300192 - China [Link]@[Link]
T +86 22 87 890 588
F +86 22 87 892 018
loitj@[Link]
[Link] [Link]
