Market

Aluminium & Non-Ferrous

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Advantage 01
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Can be applied at reverb, fix axis rotary, or tilting rotary furnaces with minor changes

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Uses a combination of company-wide approved proprietary technologies

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Reach your carbon neutrality goals whilst avoiding big capex

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Market features

Improve your specific energy consumption

By using our proprietary oxy-combustion technology adequated to each kind of furnace it could be possible to reduce your specific energy consumption up to 57%*.

Reducing nitrogen presence makes it possible to reduce NOx generation and improve your filtration system performance.

*Pending on your most recent base case

Improve your specific melting rate

Improve your specific melting rate by up to 66%* by using the proper technical approach.

After studying your furnace’s current performance, we reduce the necessary nitrogen presence and thus resulting in the reduction of energy loss within your furnace.

*Pending on your most recent base case

Accept the use of scrap with organic materials

The capacity to manage the exact require stoichiometry prevents the generation of black fumes. Directly injecting oxygen reduces the furnace pressure and permits the use of cheaper scrap without emissions. This use reduces energy demand when using organic materials as sources of energy inside the furnace.

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Oxygen use enables your carbon neutral journey
By reducing the amount of air, which contains 78% nitrogen, at your furnace it becomes more effective in energy use - reducing the CO2 emissions associated.

Oxygen use pertains to all kinds of aluminium furnaces, including tilting rotary, fix axis rotary or reverb furnaces, to more efficiently use the available energy and reduce the associated CO2 emissions. At the same time, the application of our Diluted Oxygen Combustion technology contributes to drastically reduce NOx emissions at your site whilst maintaining the highest safety standards.

Applied to these industries

Aluminium
Copper
Zinc
Lead
Titanium
Other non-ferrous metals

Applicable technologies

Discover our solutions across different markets

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We help our clients create successful solutions

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Client: Oxygen enrichment to reduce NOx emissions

Oxygen enrichment to drastically reduce NOx emissions in a green glass and flint production company.

  • A client with two end port regenerative furnaces used in flint and green glass production were looking to reduce their carbon footprint
  • The furnaces were operating at 380 and 400 tpd
  • Nippon Gases installed their proprietary technology to both furnaces, drastically reducing NOx emissions

The following equipment was installed in order to reduce the NOx emissions – all specially engineered by Nippon Gases:

  1. Main Oxygen Skid
  2. Oxygen skid control for each lance
  3. Lances with nozzles
  4. Panel view electrical cabinet
  • Before installation of Nippon Gases’ paraphernalia, the furnaces were operating at 380-400 tpd and producing 800-870 mg/Nm3 of NOx emissions at the Port Neck
  • After installation, the total NOx emissions had reduced to 590-630 mg/Nm3, showing a 26.5% decrease in emissions

KEYWORDS :

Innovation

Client: From recuperative furnace to 100% oxy-fuel furnace

We transformed an old recuperative glass furnace based on air-fuel combustion to 100% oxy-fuel for a glass company.

  • A customer with a recuperative glass furnace (52 tpd capacity) wanted to reduce the total energy consumption of their main furnace, whilst increasing production of glass. Achieving this whilst maintaining the furnace superstructure
  • We started developing a solution to substitute their old air-fired furnace to an oxy-fired one
  • The old recuperator turned defunct and the space occupied by it could be used for other purposes around the factory
  1. Together with the customer’s engineering team, we developed a customized solution to transform their old recuperative glass furnace; based on air-fuel combustion, to 100% oxy-fuel
  2. Compiling the customer’s experience on the furnace’s engineering with the experience of Nippon Gases’ Combustion Team, the new furnace was designed reusing the old super structure; elongating the old furnace footprint and doing the necessary CFD simulations and calculations in order to build a furnace capable of achieving the required glass quality – minimizing the NOx and particulate emissions
  3. The furnace entered into production with a LOX (liquid oxygen) supply, but was designed ready to incorporate one VPSA (Vacuum Pressure Swing Absorption) system some months after start-up – once the glass production entered a stable level
  4. The combustion system installed comprised of one state-of-the-art safety skid, together with the skid to control the pressure and flow of the comburent and oxidant, as well as the most advanced Dilujet JL burners capable of using the Diluted Oxygen Combustion concept (the market’s responsible for achieving lower NOx emissions for this kind of furnace)
  • We achieved the desired production level increase from 52 tpd to 65 tpd of glass, reaching the desired quality level
  • The furnace’s specific energy consumption was reduced from 200Nm3 NG/t glass to 100Nm3 NG/t
  • NOx emissions where drastically reduced and the flue gas volume also decreased in volume even when taking into account the increase of production level
  • Operators can smoothly run the new furnace without the necessity of continued supervision on the flue gas Tª to avoid damaging the recuperator that was necessary to have with the previous furnace’s design
  • The customer received our support and advice in every step of the project
  • The addition of the new VPSA system, that is capable of generating the necessary oxygen amount at the right pressure and quality, helped reduce the number of trucks that arrive every week to the plant

KEYWORDS :

Innovation

Client: Oxygen use in steel reheating furnace

We introduced oxygen into steel reheating furnace process in order to reduce energy consumption.

  • Introducing oxygen into steel reheating furnace process in order to reduce energy consumption.
  • Overview of the Mini Mill process:
  • 1. Electric arc furnace produces molten steel
    2. Molten steel enters a steel refining facility
    3. Undergoes continuous casting
    4. After which enters the reheat furnace
    5. Produces final products: structural profiles, bars, slabs, etc.
  1. Initial inspection of the furnace in order to fully understand the problem
  2. Taking into account (amongst others):
  3. - Furnace type
    - Nominal production rate
    - Actual throughput
    - Charge dimensions
    - Specific energy consumption
    - Internal pressure
  4. Split into multiple cases to properly simulate the problem and model the solutions
  5. Installed an oxygen control skid with automatic flow control (0-900nm3/h) and electric cabinet with PLC and HMI screen
  • The solution was a success, with good operation and no instances of quality problems, temperature problems or refractory damage
  • This resulted in energy savings (8.3% average), reduced CO2 emissions (4.6 kg/Ton average) and reduced production costs

KEYWORDS :

Innovation