Case Study - Alcoa Extruded Products (UK) Limited |
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Alcoa Europe manufactures aluminium extrusions in a factory at Banbury, Oxfordshire. As part of this process, they re-melt aluminium, and cast it into logs, which form the feedstock for the extrusion operation. Between the melting and casting operations, molten aluminium is accumulated in a tilting holding furnace, equipped with 3 natural gas fired burners, to ensure continuity of production and uniformity of molten metal temperature.
Problems were being encountered with achieving the required accuracy of temperature control of the holding furnace, and a review of safety equipment had revealed that the gas safety controls did not fully conform to Alcoa’s latest standards. Energy & Environmental Services were contracted to re-engineer completely the fuel gas and combustion air systems, incorporating all valves and controls necessary to comply with Alcoa’s standards. Additionally, the furnace temperature and pressure controls were to be replaced. This necessitated integrating equipment from a range of suppliers, to provide optimum performance; equipment manufactured by Eurotherm, Honeywell, Kromschroder, Dungs and other suppliers was incorporated in the scheme. Engineers from Energy & Environmental Services provided and delivered a turnkey solution to Alcoa Europe’s problems:
This project was delivered and successfully implemented to a tight time schedule, to take advantage of a short break in production.
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