Metal Minutes Case Study for Aluminium Melting Furnace Rebuild

Feature Article, Vol. 60, Issue 2 April 2002

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.” 

Owens-Corning Furnace before rebuild Owens-Corning furnace after rebuild
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.

 

SECO/WARWICK Corp

 

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©2002-2008  SECO/WARWICK Corporation, R1 8/2004, R2 12/2004