Resource efficiency at increased process quality becomes the dominating driver for investments in industry, and so in the world of casting. An optimized melting and material logistics process requires optimum temperature control of material and casting equipment, including melting furnace, transportation ladles or launders and casting moulds.
Based on its flameless high performance industry burner portfolio, promeos offers new preheating and tempering solutions all along the process line. Energy savings of up to 75% and increased process stability due to enhanced control measures have been approved at numerous foundries all across the metal processing market.
The clou is as easy as impressing: the absence of a free flame as spot-type heating source and the infinitely adjustable heat flux (similar to a dimming lamp) are core features to avoid inhomogeneity and inefficiency in heating ladles, launders or moulds.
Porous burner technology
In a porous burner the combustion takes place in a porous high temperature ceramic, the combustion reactor, instead of in an open flame. This results in a flameless, volumetric combustion in the form of glowing ceramic foam which can be used as a radiating surface as well as a homogenous source of heat.
Any forms are possible such as round or square burners, lines, cylinders, rings, rhombuses and other specially tailored shapes.
Special applications require special solutions, for example line shaped burner heads which concentrate the heat from convection and radiation exactly where it is needed.
The length of a reactor can thus be extended if desired. Dimensions of several meters in length with a reactor width from 15 - 200 mm allow specific burning performances from 2 to 600 kW / m in length.
Based on the unique features of the flameless porous burner combustion technology, promeos develops and manufactures tailored heating systems for process applications.
Furnace engineering is required for both process technology and manufacturing to ensure optimum product quality. The outstanding design features of our burners and its ease of integration into any kind of apparatus allow the heat to be distributed over / into the required area / volume an applied where the process needs it, as opposed to being directed to only one spot. We supply "tailor made suits" for your individual needs, powerful and efficient.
The unique combination of features like the power density, a rapid and precise power adjustment (similar to electric heating devices), a homogeneous heat flux and its compact and modular design result in the following benefits:
- enhanced quality of your products
- increased performance
- reduced warm-up time or start-up time of your equipment
- energy saving potential of up to 70% for your processes
- operational cost saving of 50% by substituting electrical heating systems
Heating systems for casting moulds: higher production rates, quicker & more precise preheating
The final step in the casting process is the most sensible - the temperature profile of the casting tools is essential for the quality of the products. Since every individual mould requires its optimum heating device, promeos offers customized heating tools, individually adapted to shape and process.
The modular "Lego-like" design of the burner units using the flame-free porous burner technology enables promeos in a unique way to design "custom-made suits" for different tools at reasonable cost. Optimum mould preheating, leading to significantly reduced scrap production ("initial casting") is not longer a miracle. The required investments pay back in less than 18 month - a must in times of increasing resource efficiency constraints.
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Ladle heating systems: preheating allows energy savings of 60%
The transport ladles lined with refractory material are heated to a target temperature in the empty state. A well-adapted insulated cap, which includes the burner, is placed on top of the ladle. The burner transmits the heat onto a radiating body which transfers the combustion energy as infrared radiation to the lining of the ladle.
The heat is homogeneously and effectively transmitted all over the ladle wall. The hot gas flow is directed to the bottom of the ladle and afterwards through a narrow slot between the radiating body and the lining of the ladle to the hot gas outlet, whereby the heat transfer is additionally improved. The promeos ladle heating substitutes existing "fires" to closed systems with energy savings of up to 65%. It therefore combines maximum energy efficiency with ideal industrial safety and maximum process reliability.
Reliable Drying and Sintering: The variable power control enables the realization of exact given drying and sintering profiles and in addition an optimum stand-by functionality with minimum energy consumption. Promeos' ladle heating systems - convincing and reliable solution for an optimum casting process.
Heating of launders and filterboxes: for a better process control
The above explained advantages of homogeneously and efficiently heated ladles are also valid for launders and filter boxes - the better the material transportation systems, the better the casting quality!
Promeos burner systems, integrated into the lid of filter or into the covers of lauders provide a homogeneous heating of the filter and the refractory lining. While hot spots are avoided and the lifetime of the refractory is enhanced, the temperature loss of the liquid metal can be reduced tremendously. Increased energy efficiency by reduced melting temperatures and improved material quality are evident.
NEW: Hot air heating system for industrial applications
promeos offers a compact and mobile, robust and modular hot air heating system for industrial applications - to be used for drying, pre-heating, tempering or whatsoever.
Operating mode: The exhaust gases of the central burner are mixed with secondary air in a compact mixing chamber inside of the heating system. While the burner control defines the heat capacity, the air (heating) temperature can be controlled by the ratio of exhaust gas and secondary air mass flow:
The hot air is offered as point source, line source, area source or 3D source using different nozzles, almost unlimited applications flexibility, which was only known from electrically heated blowers up to now.
promeos offers "gas heat in electric quality" without the existing shortcomings of electrical hot air guns such as limited temperature, limited power density or limited lifetime due to unsatisfying robustness.
The hot air heating system from promeos is designed even for rough boundary conditions, such steel plants and foundries etc.. It is both robust and compact and can be used stationary and as mobile heat source. A crane hook and transportation wheels enables the user to move it quickly where it is needed.
Benefits:
While the cost saving potential of 50% through substituting electrical energy by gas is self-arguing, a CO2-reduction of > 60% in DE and most world markets is worth to be mentioned.
promeos has set new standards in pre-heating solutions for the casting industry. Based on its unique combustion technology, promeos developed from a technology supplier to a reliable system manufacturer and service supplier. Energy efficiency, product quality and process reliability were and are the driving force. Future subjects in product development focus on a new type of melting and tempering furnace and further energy efficiency improvements including internal energy recovery by combustion air preheating.
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| promeos GmbH is a leading supplier. For further information and contact details click here: promeos GmbH |
