Premium technology as a service
EBNER Industrieofenbau | Michael Schiesser, EVP Customer & Sites Service
Premium technology as a service
EBNER expands its service portfolio to include non-EBNER heat treatment facilities.
For decades, as the world’s leading manufacturer of industrial facilities for the aluminum, steel and copper base metal industries, EBNER has stood for high quality, technological Innovation and tailor-made heat treatment solutions.
Since the beginning of this year, EBNER has been placing additional emphasis on a strategically vital business sector: the modernization and service of, as well as the supply of components for, heat treatment facilities that were not manufactured by EBNER itself.
This expansion of EBNER’s portfolio of services is, however, not entirely new. In the past, a number of successful modernization projects have been carried out at competitor’s facilities. One outstanding example of this is the complete modernization of the automation and visualization systems of a 32-workbase bell annealer facility in Italy, over the course of which EBNER demonstrated its expertise in control technology and process optimization. The facility was not only revamped to meet the latest technical standards, but its efficiency and ease of operation were significantly improved through installation of the VISUALFURNACES® Process Control System (PCS).
Another successful project was the integration of EBNER ECOBURN technology into a non-EBNER facility to reduce NOx emissions. Implementation of this extremely efficient burner technology meant that exceptionally low emission values could be achieved – making a significant contribution to sustainability and compliance with future environmental protection standards.
Another focus is being placed on the design and fabrication of inner covers and workbase components for bell annealers processing steel strip or steel wire. These pieces of equipment are customized to suit individual needs, and fulfill the highest standards for safety, durability and thermal efficiency. A particular highlight is the workbase repair kit specially developed by EBNER, which ensures that a facility is shut down for the least possible amount of time. It is installed on site, minimizing interruptions to production and maximizing cost effectiveness.
The ability to install premium technology at non-EBNER facilities offers the operators of existing facilities a decisive advantage: they can modernize their current systems and, at the same time, take advantage of the latest developments and innovations from EBNER – without needing to make a completely new investment.
With this strategic expansion, EBNER has positioned itself to be more than just the technology leader. It is also a reliable partner for the modernization and optimization of existing heat treatment facilities, regardless of their original manufacturer. Customers can benefit from tailor-made solutions, short shutdown times and access to state-of-the-art technologies that pave the way into a more sustainable and efficient future.
EBNER can adress a wide variety of issues that are crucial for the future of heat treatment. They include:
ELECTRIFICATION AND HYBRID HEATING
Our electric heating systems can be easily integrated into existing furnace systems. We offer future-proof solutions that fulfill the strictest regulations, even as they provide longterm reductions in operating costs.
Our product range includes:
- Coiled Heating Elements – compact, powerful heating elements for precise temperature control
- Resistor Elements – durable resistance heating elements for industrial applications
- HICON Plate Heater – patented, high-performance heating system developed by EBNER for the efficient and even distribution of heat
Thanks to their modular designs, our components are ideal for retrofitting into existing systems. Make the switch to electric heating quickly, efficiently and sustainably.
COMBUSTION AND DeNOx
State-of-the-art burner technologies such as EBNER ECOBURN reduce emissions to a minimum and fulfill the most stringent environmental regulations. The use of technologies like ECOBURN FL (flameless) or ECOBURN H2 FLEX (H2 + CH4) can lower NOx emissions by up to 60 %. Exhaust gas recirculation and atmosphere outburners raise energy efficiency even further.
- ECOBURN FL Flameless Burner
- ECOBURN H2 FLEX Dual-Fuel-Burner
- SCR / SNCR DeNOx-reactors
ATMOSPHERE AND GAS SAVINGS
Optimized process atmospheres and reductions in gas consumption lower operating costs and reduce environmental impacts.
MECHANICAL AND THERMAL MANAGEMENT UPGRADES
Upgrades to mechanical and thermal systems extend the service life and efficiency of an existing heat treatment facility. EBNER supplies custom-fit inner covers, insulation and mechanical components – tailored to match existing circumstances like atmospheres, temperatures, peripheral components and customer requirements. The dimensions of materials, alloys and types of weld seams are carefully selected, while fabrication is carried out in one of the EBNER workshops scattered across the globe to ensure rapid delivery.
- Impellers and recirculation fans
- State-of-the-art insulation and lining kits, developed in-house
- Efficient furnace inlet locks for continuous facilities (e.g. floater furnaces)
- Penetration thermocouples for pusher furnaces
IHRE VORTEILE AUF EINEN BLICK
Substantial energy savings through improved insulation and optimized inlet sections
- Shortened cycle times while product quality remains unchanged
- Rapid amortization due to measurable improvements in efficiency
An EBNER retrofit won’t just future-proof your facility – it will significantly improve its economic attractiveness.
WASTE-HEAT RECOVERY
Compact and efficient recuperators and high-quality heat exchangers allow the recovery of thermal energy from hot streams of exhaust gases. This energy can be used to directly preheat combustion air, generate steam or heat buildings through an HVAC system. The results: perceptible savings and an amortization period that can be measured in months instead of years. Our product range includes:
- Heat recovery systems – for the efficient use of waste heat
- Large recuperators – powerful thermal energy recovery for large-scale facilities and high-volume gas flows
Integrating our solutions into an existing facility is simple and straightforward, offering an easy way to lower operating costs and carbon emissions – without compromising the quality of your process.
DIGITAL & AI PROCESS CONTROL
Intelligent process control using algorithms supported by AI for maximum transparency and efficiency.
PLC/AUTOMATION SYSTEMS MODERNIZATION
Modernization of PLCs and automation systems to provide future-proof control systems.
MEASUREMENT AND SENSORS
Integration of cutting-edge sensor systems for accurate supervision and control of processes. Extremely accurate sensors and state-of-the-art measuring systems allow the uninterrupted supervision and control of a heat treatment process. Our new temperature measurement system enables you to carry out a Temperature Uniformity Survey (TUS) or take measurements during water quenching – with minimal facility downtime. Thanks to its rapid installation, durable insulation and 6-channel data logging system, it allows an entire solution annealing process to be accurately and reliably mapped.
YOUR ADVANTAGES AT A GLANCE
- Complies with AMS 2750 and CQI-9 for Temperature Uniformity Surveys (TUS)
- The entire process is covered, including water cooling
- Watertight, easy to use and extremely reliable
PROCESS OPTIMIZATION AND R&D SERVICES
Our R&D services assist you in continuously improving processes: EBNER offers extensive support for the development and optimization of your heat treatment process, from the initial idea all the way up to implementation at production scale. Our Research and Development Department combines a deep understanding of heat treatment processes with cutting-edge technology, allowing them to develop tailor-made solutions that meet your specific requirements.
OUR SERVICES AT A GLANCE
- Modeling, simulations & prototyping
Using advanced approaches to simulation like CFD (Computational Fluid Dynamics) and FEM (Finite Element Method), we analyze thermal and mechanical processes and atmosphere flows. New designs are tested in our pilot and prototyping facilities under realistic conditions. - An extensive, well-equipped lab
A wide variety of modern testing instruments are available to provide accurate material and process data: Hardness testing/microscopy/chemical analysis/Epstein testing (to assess magnetic properties) - Individualized testing plans and consulting
Our R&D experts develop tailored testing plans and stay by your side during trials – from test anneals to component anneals and the analysis of samples. - Process optimization
Based on the data that were collected and the results of the simulations, we provide support during the targeted optimization of your heat treatment process – for more efficiency, quality and sustainability.
GLOBAL SERVICE
Individualized service and maintenance agreements for heat treatment facilities allow EBNER to make sure that existing systems – regardless of manufacturer – continue to perform at their maximum. Whether through the replacement of mechanical components, the optimization of a heating system, the replacement of insulation or the installation of an energy-efficient upgrade: our services improve facility availability, lower energy consumption and extend the service life of your investment. Thanks to our decades of experience and the global reach of our manufacturing centers, we can guarantee rapid implementation and sustainable results – for more efficiency, less downtime and maximum operational safety.