With its new, patent-pending dual-layer fluidized-bed furnace, Wire KÖRNER cuts capital, energy and maintenance costs for its customers in the wire processing industry, while enhancing the quality of the end products.
This innovative furnace design does without a number of components which used to be considered indispensable in the past - such as, for example, the complex and expensive distributor tiles, perforated distribution pipes and stand-by blowers.
The absence of distributor elements markedly reduces the flow resistance inside the furnace. Hence the required blower capacity can be lower than that of competing designs by about 20 percentages.
Through carefully customized control algorithms, efficiency is maximized at all loads. This saves up to 15 percentages energy. For a typically sized furnace this means more than 7,000 Euros per year saved on energy.
The combustion gas is premixed outside the furnace. This makes for a uniform gas-air mixing ratio throughout the fluidized bed.
The advantages are uniform temperature distribution over the complete width and length of the furnace, high heat transfer efficiency and optimal end product quality.
Wire KÖRNER has made the furnace design substantially simpler. The actual fluidized bed rests on a layer of coarse grit, which serves as a filter layer. The individual grains of the sand are big enough to be held in place when the air-fuel gas mixture is flowing through the voids from below. In contrast to this, the fine grit above the filter layer fluidizes, transferring the thermal energy into the wire.
This design makes pipes, grates, distributor tiles and additional blowers for cooling superfluous. The overall simplified furnace design markedly reduces capital costs. The new design also no longer requires a stand-by blower in the event of a power failure to provide cooling air to cool the steel structures, which were necessary in the past.
Wire KÖRNER has also reduced the maintenance effort as there are fewer components to be maintained. For example, having to replace distributor elements has become a thing of the past.