Publication
New OTTO JUNKER
billet heater in place
at MKM Hettstedt
Carsten Homann
MKM Mansfelder Kupfer und Messing GmbH, Hettstedt
Patrick Leidenroth
MKM Mansfelder Kupfer und Messing GmbH, Hettstedt
Eberhard Topf
MKM Mansfelder Kupfer und Messing GmbH, Hettstedt
Jan van Treek
Otto Junker GmbH, Simmerath
Otto Junker GmbH
Jgerhausstr. 22
52152 Simmerath
Tel.: +49 2473 601 0
Fax: +49 2473 601 600
Internet: http://www.otto-junker.de
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New OTTO JUNKER billet heater in place at MKM Hettstedt
Otto Junker GmbH and MKM Mansfelder Kupfer- und Messing GmbH of Hettstedt/Germany,
the noted copper and brass processing company, are glad to report the successful start-up of
a new gas-fired billet heater. The new system replaces a previous heater supplied in the
early 90s which was designed mainly for brass stock at the time. "After close to 20 years,
and in the face of an altogether different set of requirements, investing in a replacement was
the logical step for us", recalls Eberhard Topf, Head of Maintenance for the tube/rod product
segment at Mansfelder Kupfer- und Messingwerke. "Given our good experience with the old
system and the truly convincing concept, our choice fell on OTTO JUNKER once again."
The new design is aimed mainly at lowering the energy consumption, in addition to achieving
a better heat distribution throughout the billet and improved ease of operation.
Fig. 1: Overall view
In order to maximize the efficiency of the heater plant, a number of measures were taken.
Thus, OTTO JUNKER developed new burners which deliver a higher fuel efficiency and can
operate on preheated air for combustion.
The exhaust gases first pass through the exhaust duct above the heating chamber into a
heat exchanger which uses part of the energy for preheating the combustion air. From here
the still hot exhaust gas is fed into the 18-metre-long preheating zone which consists of three
individual preheat chambers. In these chambers, the hot gases are repeatedly blown onto
the billets at high velocity.
OTTO JUNKER GmbH
Jgerhausstrae 22
52152 Simmerath
Tel.:
+49 2473 601-0
Fax:
+49 2473 601-600
Internet: www.otto-junker.de
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Thus, a large portion of the energy still present in the exhaust gas is used to preheat the
billet before the exhaust gas is discharged into the stack at a temperature of around 200C.
Such energy as it still carries is then further utilized in part by MKM for its hot water supply,
so the energy input is exploited to the fullest extent possible.
The newly developed burners and the optimized burner arrangement in the heating chamber
make for an improved heat transfer into the billet. In addition, a tight-closing door was fitted
at the heater exit end. "Together with the refined walking beam sealing system, the heating
chamber is thus sealed off as effectively as possible to keep the energy inside the heater and
to prevent any ingress of oxygen", reports Jan van Treek, Project Manager at OTTO
JUNKER.
Fig. 2: View of the heater interior
Ease of operation is ensured by the proven walking beam system of OTTO JUNKER design.
"The walking beam allows us to work with a gap of a few millimeters between the billets,
which effectively prevents them from sticking. Inside the heater this gap will close again as a
result of the thermal expansion", Eberhard Topf explains, describing another major benefit of
the new system. Pyrometer-based temperature measurements taken vertically from above,
in conjunction with the walking-beam system, facilitate changeover between different billet
diameters. Another highlight is the redundant temperature monitoring feature: along with the
proven temperature profile which ensures step-by-step heating of the billet column and
adapts dynamically to the press cycle, the temperature of the heating chamber is now
monitored as well for increased safety.
Billet discharge is effected by means of a gripper car which enters the heater chamber to lift
the billet up and extract it from the heater. The car transfers the billet to the overhead crossconveyor supplied, which places the billet directly in MKM's billet loader. This design
effectively minimizes the furnace-to-press transfer time.
OTTO JUNKER GmbH
Jgerhausstrae 22
52152 Simmerath
Tel.:
+49 2473 601-0
Fax:
+49 2473 601-600
Internet: www.otto-junker.de
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Fig. 3:
Billet discharge
The visualization system allows the operator to check all key parameters at a glance and to
track all billets related to each given job.
Upon completion of pre-assembly the customer used the opportunity to inspect the system at
Junker Industrial Equipment in Czechia and to carry out some advance functional tests. In
the course of this visit, MKW was impressed by the production capacity in place and by the
solid build quality of the equipment.
Now that the system has been successfully commissioned, more benefits are becoming
evident.
The new system has enabled us to outperform a 10-year-old production record this year.
Moreover, we havent had any sticking billet problem yet, whereas these used to occur at
least once a month with the old system, explains Patrick Leidenroth, Manager of Tube/Rod
Production. And we have been able to increase our product quality further, which implies
additional benefits for ourselves but most of all for our customers as well.
OTTO JUNKER wishes to thank MKMs staff for the pleasant and constructive cooperation.
The system thus put into place has set new standards in heating of copper billets, providing a
cost-efficient technology that combines high performance with a maximum of safety and
reliability.
OTTO JUNKER GmbH
Jgerhausstrae 22
52152 Simmerath
Tel.:
+49 2473 601-0
Fax:
+49 2473 601-600
Internet: www.otto-junker.de
Anlagenbau
Gieerei
