Vertical Billet Heaters

Thermatool™ Vertical Billet Heating systems are designed for precision heating of billets made from steels and other alloys prior to extrusion.
Thermatool engineers have responded to the challenge of uniformly heating billets for the extrusion process, applying over 40 years design and manufacturing experience gained from specialist induction heating applications. As a world leader in the design and manufacture of Low Frequency Induction (LFi) power supplies, Banyard also offers customers extensive electrical control and mechanical handling expertise, delivering turnkey solutions.
The result is Vertical Induction Billet Heating systems, offering the latest in proven technology whilst delivering fast, accurate and highly repeatable induction heating of billets. Thermatool Vertical Induction Billet Heating systems offer customers total reliability and low maintenance costs prior to the extrusion process.
Thermatool™ Vertical Induction Billet Heating systems are designed for precision vertical induction heating of solid or pierced billets and tubes with diameters over the typical range 150 mm to 460 mm, and lengths between 300 mm and 1500 mm. Full systems include multiple heating stations to give the overall system throughput to meet the demands of the extrusion press.

Product Details

Features

Induction Coil & Power Converter

Each heating station includes a low frequency power converter with selectable frequency control independent of power demand and set of induction coils configured to the needs of the customer. With options for single or multi-zone control, our advanced closed loop control enables billets to be uniformly heated to their target temperature even when the initial temperature uniformity is poor – or the starting internal billet temperature is unknown.
Single-zone systems with an automated coil tap selector vary the coil length for heating a wide range of different billet lengths.
Multi-zone systems with zone control enable control of the temperature profile along the billet length and allow for compensation for non-uniform starting temperatures.

Billet Up-Ender / Charger Unit

Pre-heated billets are discharged sideways to the heating station up-ending units by a pusher to a transfer ramp from the cold billet shuttle conveyor. The transfer ramp holds the billet, awaiting the control signal for the billet heating to commence. The transfer ramp then loads the billet into the up ender. This orientates the billet in a vertical position and raises it into the vertical induction coil via an electric lifting actuator. The hot billet is then lowered and discharged sideways onto the hot billet trolley conveyor.

PLC System and Operator Interface

A standard PLC control system is provided based upon Siemens S7® series components for the control and sequencing of all induction heaters (pre-piercing and pre-extrusion), conveyors and up-ending/charging units. The system includes SCADA for data logging and recipe management.
The system includes distributed I/O at the individual heating stations and an operator console which can be located at the press operator’s position. The operator’s terminal includes an HMI panel for entry of production parameters and system status display.

Minimising Oxidation (Scale)

The induction coils include a top hat assembly mounted on top of the coil to significantly reduce convective heat loss and to provide containment when using a controlled atmosphere.
Inert gas ports are provided at the base of the coil to allow for a controlled atmosphere inside of the induction coil. When combined with reduced heating times, this results in significantly less oxidation and scale formation when compared to traditional oven heating.

Benefits of VSI technology

High circumferential temperature accuracy and repeatability. i.e. better temperature distribution.
Greatly increased billet hold times while maintaining temperature uniformity.
Ability to process billets from different materials with minimum oxidation and scale (utilising controlled atmosphere technology).
Individual heating of billets results in no billet-to-billet fusing.
Low glass lubricant build-up.
Flexibility of operation with very low levels of rejected billets.

Siemens S7® is a registered trademark of Siemens Trademark GMBH & Co. KG.

Tech Specs

Billet heating is controlled though use of optical pyrometers to provide continuous temperature measurement, with the option for a second device to act as a fail-to-safe temperature check policeman.
Rapid heating times are attained by utilising low coil frequencies, enabling deep heating penetration, all while maintaining high heating efficiency, and ensuring that surface temperature maximum setpoints are not exceeded.
Billet end temperatures are controlled using our patented flux extender technology (European Patents EP2 236 005 B1 and United States Patent No. US10 034 331 B2 for method and apparatus). This technology extends the magnetic flux beyond the ends of the billet and, with adjustable coil length and frequency, ensures uniformity along the billet length. It can also be used to overheat the billet ends to compensate for thermal transportation losses.
Billet core temperatures are heated to uniformity using an advanced closed- loop control algorithm that determines core uniformity independent of starting temperature. This allows for re-heating of partially heated billets without the need to reject them.
Heat Station compensation can be used to automatically heat billets to elevated temperatures in relation to each stations distance from the press. This provides compensating for variance in thermal loss during billet transportation.

LFi power convertor specifications:

Power rating: 200 kW to 1000 kW
Selectable frequency from 20 to 200 Hz
Supply: 400-480 V 3-Phase
Power factor: 0.95 (Constant)
Conversion Efficiency >94%
Independent power and frequency control.
0 to 100% step-less power control

Product Images

Banyard - Vertical Steel Induction Billet Heater (3)

Banyard - Vertical Steel Induction Billet Heater (4)

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Interested in this product? Connect with an Inductotherm Group company in your region to learn more.

Thermatool Corp.

31 Commerce Street, East Haven, CT 06512 USA

+1 (203) 468-4100 | info@thermatool.com

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Inductotherm Group Australia

62 Bardia Avenue, Seaford. Victoria 3198
Australia

+61-3-9786-6000 | furnaces@inductotherm.com.au

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Inductotherm Group China

Inductotherm Industries (Shanghai) Ltd.
50 Guoshoujing Road, Zhangjiang High-tech Park, Pudong, Shanghai
+86-021-3895-3220 I sales@inductotherm.com.cn

Inductotherm Group China Ltd.
92 Ximei Road, Xinwu District, Wuxi, Jiangsu

+86-510-8523-1010 | sales@inductotherm.com.cn

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Inductotherm Group Indonesia

JI. Flores II Blok C7 No. 4, Kawasan Industri MM 2100,
Desa-Mekarwangi - Cikarang Barat Bekasi, Jawa Barat Indonesia 17520

+62-21-89982005 | info@inductotherm.co.id

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Inductotherm Group Japan

1-3-10 Mibemibefu,
Nishi-Ku, Kobe 651-2116 Japan

+81-78-974-2552 | info@inductothermgroup.jp

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Inductotherm Group Korea

188 Dasansandan-ro, Dasan Myeon
Goryeong-gun Gyeongsangbuk-do Korea 40113

+82-54-954-5682 | inductotherm@inductotherm.co.kr

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Inductotherm Group Taiwan

10, Gongye W. 5th Rd. Lukang
Changhua County 505004 Taiwan (R.O.C.)

+ 886-4-7811630 | sales@inductothermgroup.com.tw

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Inductotherm Heating and Welding

Thermatool House, Crockford Lane
Basingstoke, Hampshire, RG24 8NA

+44 (0) 1256 335 533 | info@inductothermhw.co.uk

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Inductotherm Group Türkiye

Muallimköy Mah. Aşağıbağlar Cd. No:41 P.K. 47 41400 Gebze / KOCAELİ / TÜRKİYE

+90-262-646-3424 | inducto@inductotherm.com.tr

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Inductotherm Group India

INDUCTOTHERM (INDIA) PVT. LTD.
Plot No. SM-6&7, Road No.11 Sanand-II, Industrial Estate, BOL Village, Sanand Ahmedabad- 382170
Toll free: 1 800 419 2900
Sales: +9193745 78586
Spares: +9193279 80564

+91 271 762 1000 | sales@inductothermindia.com

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