Rebuild Project Nets 35% Fuel Savings for Owens-Corning Metal Systems

By Al Reinhart, SECO/WARWICK Corp., USA, areinhart@secowarwick.com

Rebuilding two stationary melting furnaces increased production and reduced fuel costs.

In January 2002, SECO/WARWICK completed a rebuild of (2) stationary aluminum melting furnaces at Owens Corning Metal Systems in Richmond, Virginia (Bellwood Plant).  At the beginning of the project, SECO/WARWICK performed a complete system design review, then provided a complete turnkey project.   In addition to engineering and construction services, SECO/WARWICK provided Owens-Corning with a comprehensive staff training program for both the operation and maintenance of the equipment.

Steven Piciacchio, Owens-Corning Metal Systems Plant Manager had the following comments:

“We recently contracted SECO/WARWICK for combustion system and refractory upgrades for two of our melting furnaces.  The projects entailed structural modifications to the charge wells, installation of a regenerative burner system, and refractory modifications. SECO/WARWICK offered the most competitive package and finished the job on schedule and within budget.  Our furnaces are now capable of achieving historical production rates while utilizing 35% less fuel.  We would recommend SECO/WARWICK  rebuild services to any manufacturer interested in a quality job at a competitive price.” 

Furnace before Rebuild	Furnace after Rebuild

SECO/WARWICK provides a full range of services for non-ferrous melting furnaces including: 

• Structural Modifications
• Control up-grades including PLC programming
• Combustion system up-grades and conversions:
        Regenerative systems
        Oxygen-fuel systems
        Recuperative systems
• Refractory design, installation and dry-out
• Door, seal, and lintel modifications
• Pressure control systems
• Auxiliary equipment
• Molten metal transfer launders
• Filter and degas units
• Field Services - troubleshooting to flue gas analysis

Maintenance agreements and training services are available and can be tailored to suit individual company requirements.

USA • Poland • China • India

©2002-2009  SECO/WARWICK Corporation, R1 8/2004, R2 12/2004, R3 1/9/2009