We at Agrati have always been committed to improving the energy and environmental sustainability of our production processes. The study with AIM about the intervention focused on “Sustainability in heat treatment” gave ample evidence of this.
As early as the 1980s, we began to study how to reduce the high energy impact of these processes. These efforts have been intensified over the past decade through innovative, cutting-edge solutions.
The goal has always been to reduce waste in thermal, heat or raw material processes.
HOW TO ACHIEVE WASTE REDUCTION GOAL?
In the heat recovery lines (quenching and annealing furnaces), different recovery systems have been provided:
- We recuperate residual heat from the burner gases of the hardening furnace burners (at over 400°C) for reheating the previous washing stages;
- We reuse the heat that accumulates in the oil and emulsion quench tanks for winter heating of the factory and the intermediate washing machine at the lines;
- Since 2017, a system for cleaning and recovering tempering oil has been in operation, similar to what has been in use for years for molding oils.
The effectiveness of these systems has also been confirmed by a recent study conducted in collaboration with the Politecnico di Milano.
THE ACHIEVEMENTS
The just mentioned interventions allow a reduction in gas consumption, for the Veduggio site alone, by about 4,000 Smc/day and in tempering oil consumption by 35 percent. We have therefore extended them to almost all similar plants of the group.
For the wire rod annealing furnaces (present only at Veduggio), we have then designed a heat recovery system from the hot furnace fumes. This supports the heating of the tanks of the adjacent wire rod pickling plant, reducing gas consumption by about 10 percent.
The even more recent revamping of Ferrè’s two reannealing furnaces has also significantly increased their thermal efficiency and modernized the process heat recovery systems. In doing so, specific gas consumption for reheating has decreased by nearly 35 percent.
AGRATI DOESN’T STOP HERE
We are implementing a cogeneration plant (i.e., joint production of electricity and heat) in Veduggio. This will further increase the efficiency of gas heating systems, both process and air conditioning.
Many issues are still open in the area of heat treatment (flameless burners, self-generation of nitrogen, etc.). But Agrati will not stop investigating.
The goal? Constant and continuous improvement of the efficiency and sustainability of our processes.