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Better energy values and fewer charging operations
In 2013 , ZPF GmbH emerged as the successor to ZPF therm Maschinenbau GmbH , focussed primarily on the development and construction of highly efficient aluminium melting furnaces . The company ’ s first furnace has already proved its worth at Metallwerk Friedrich Deutsch , which also operates one of the first ‘ ZPF ’ furnaces built in 1993 .
Economic , environmentally-friendly aluminium melting technology has always been the primary focus of ZPF therm Maschinenbau GmbH . Since November 2013 , these tried-and-tested and continuously improved melting furnaces have been produced under the name ZPF GmbH . The first installation was delivered in February 2015 , not entirely by chance to a customer who is still operating six first generation ZPF furnaces from 1993 . Metallwerk Friedrich Deutsch GmbH in Innsbruck , Austria is a market leader for ski edges and a major supplier to the automotive industry . Thanks to the company ’ s positive experience and satisfaction with the furnace engineering from ZPF in Siegelsbach in the past , the decision was taken to continue the working relationship with the successor ZPF company . The plant is running at full capacity and has already proved to be exceptionally economical .
Capacity expansion The Friedrich Deutsch metal working factory in Innsbruck is known primarily for its pre-shaped and partly pre-finished steel edges for the ski and sport industry . In addition , the company manufactures pressure diecast aluminium components for all prominent European car producers in Europe ; with several thousand tonnes of material melted every year . Until recently , this work has been undertaken via six melting and holding furnaces from ZPF therm in 24h continuous operation . “ An expansion was necessary for capacity reasons , however ” explains Hubert Tilg , Manager of the diecasting division . “ Because we were absolutely satisfied with the existing furnaces and they offer an excellent price-performance ratio as well , it was clear that we would again opt for ZPF .”
A further factor was that because of the customer ’ s familiarity with these melting facilities , the staff could continue to carry out most maintenance duties on the new furnace in-house . Within three months , the required installations were manufactured at Siegelsbach , Baden-Wuerttemberg and delivered to the customer . The system consists of an aluminium melting furnace with a melting capacity of 1500kg / h and a holding bath for 5000kg , an attached charging machine and a 17in filtering furnace for cleaning the molten metal . “ Thanks to its size , the new melting furnace yields much better energy values and is thus even more economic than the previous systems ” says Mr Tilg . “ Apart from that , the larger charging system doesn ’ t need to be loaded so frequently , a further factor which reduces energy consumption and increases performance .”
Environmentally-friendly construction ZPF furnace engineering is aimed at keeping energy consumption as low as possible and implements flue gas reversal to achieve this goal . Instead of the hot flue gases from the melting process being discharged straight away , they are routed inside the furnace in such a way that their heat can be used to hold the molten aluminium at a high temperature . In addition , the combustion chamber made of refractory concrete acts not only as a separating layer between the aggressive liquefied aluminium and the outer shell of the furnace but also as insulation , reducing the emission of heat to the surroundings and functioning as an energy accumulator . It is consequently much easier to keep the temperature inside the furnace at a constant level .
In combination with waste gas recirculation , the fuel requirement is very low , making the furnace particularly efficient and environmentally-friendly . At the same time , the longer route of the waste gases inside the melting system brings about lower emission values since practically all pollutants are burnt in the post-combustion process at over 800 ° C . This means that ZPF installations can be used without flue gas filters . Furthermore , ZPF technology has an impact on melting quality and the maintenance costs ; the waste gases remaining inside the furnace generate a slight overpressure , which prevents additional oxygen from entering . The adverse reaction of oxygen with aluminium – which would cause corundum to form in the melt and on the inside walls - can consequently be kept at a low level . This technique achieves a higher degree of purity in the liquefied aluminium , as well as reducing damage to the refractory walls , thus avoiding expenditure for relining and repairing the plant .
Longstanding business relationship The melting furnace has been working at full capacity without problems since commissioning last February . “ We already have one of the first – if not the first – furnace made by the former company ZPF therm and that is still in operation today . And we will continue working very closely with ZPF ” explains Michael Deutsch , CEO of Metallwerk Friedrich Deutsch . “ ZPF is a partner with true ‘ handshake reliability ’, with whom you can go through the ups and downs of life . As a result of the new ownership , our confidence has increased even further .” The company is already considering ordering a further furnace in the medium term as an additional safeguard for the event of breakdowns . www . zpf-gmbh . de
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Cast Metal & Diecasting Times April / May 2016