Main Content

Advanced Ceramics

Kilns and Furnaces

Eisenmann has experience with all established kiln and furnace types. From the chamber kiln to the gas-tight roller-type kiln with vacuum gate, we are proficient in the entire range of kiln systems. Our engineers understand the advantages and disadvantages of the different concepts and can select the appropriate concept depending on the requirements. If required, we combine existing concepts available in our comprehensive construction kit.

Our vast experience in implementing diverse systems forms the basis of our continuous further developments:

  • Roller-type kilns
  • Tunnel kilns
  • Firing rack kilns
  • Pusher plate kilns
  • Push-through kilns
  • Mesh-belt kilns
  • Walking beam furnaces
  • Shuttle kilns
  • Lift carriage kilns
  • Lift-base kilns
  • Chamber kilns
  • and many more

If none of the systems fit your requirements, we will simply develop the appropriate technology!

As simple as possible, as complex as required!

In the past, the requirement of different atmospheres in kilns and furnaces in the successive phases of a thermal process could often only be met by discontinuous systems. The conviction that production in continuous systems is considerably more efficient and better reproducible has inspired Eisenmann to develop a gas-tight and – as required – even vacuum-tight roller-type kiln. In gas-tight or vacuum-tight roller-type kilns, e.g. when sintering powder metal components, the successive kiln zones are operated with different process gases or in a vacuum according to the process requirements. For an optimum separation of the zones from each other, the following gate systems are used as locks according to the requirements: adjustable stream barrier, stream-tight gate, gas-tight gate, vacuum-tight gate - E|GATE.

The use of the gate systems in a roller-type kiln enables an optimum separation of the atmosphere areas. The roller drive makes it possible to draw a production unit from the process zone into a lock while the feed motion continues. In this case, the atmosphere can be changed without restriction before the unit is handed over to the next process zone and is integrated into the continuous feed again.

Technical Ceramics and New Materials

With our plants we provide comprehensive process know-how for optimizing all the process parameters according to your product. Eisenmann has introduced distinctive new developments in many sectors of the ceramics industry. In this context, the productivity could be increased, the quality enhanced and the entire production flow directed to new grounds.

Typical sectors of success for Eisenmann: electronics, automotive, aerospace, medical ceramics, catalytic converters, diesel particulate filters, fuel cells, ceramic brakes, photovoltaics, battery systems and many more.

From the pilot plant to highly-efficient production lines

Eisenmann supports you throughout the entire product life cycle. Our process engineers analyze your requirements and discuss the technical solutions with you. Wherever required, our specialists use the possibilities provided by our Technology Center and develop tests to assure novel technical or process engineering solutions in advance.

In this process, we never loose track of the requirements with respect to scalability. Eisenmann makes use of vast experience in implementing complex processes, from the pilot plant up to the fully automatic production line. Whether complex processes can be scaled to continuous systems with a manageable risk is often determined as early as in the layout phase of the pilot plant.

For our job, we have an extensive construction kit of already implemented plant systems at our disposal. We are familiar with all the established furnaces and kilns.

Material Flow

The optimum connection of kiln systems with the upstream and downstream production processes looks back on a long tradition in out house. In the production of ceramic parts, Eisenmann has virtually revolutionized the material flow, e.g. with the first fully automatic production line for the manufacture of porcelain or with the development of linked sintering lines with fully automatic layer buffers for manufacturing electrotechnical ceramics. Understanding the interdependencies in linking automation technology with sensitive kiln technology is crucial for selecting just the right techniques.

Everything from one Source

Only when embedding high-class kiln technology into a coherent material flow concept will your production result in a highly efficient production line. Only the understanding of kiln technology combined with a good command of a broad range of conveyor and automation systems provides the basis for optimum integration and alignment with each other and for avoiding problems in the complex interface between the systems. The key to an effective implementation of a lean, automated production is the perfect control of the kiln systems. Only when process engineering in the kiln operates in a stable and reliable way even with considerable load fluctuations, is it possible to design automation that is simple and thus effective.

Eisenmann has a broad range of solutions for material flow designing available:

  • Roller conveyors
  • Carrying chain conveyors
  • Belt conveyors
  • Power & Free conveyors
  • Electrified monorail system
  • Automatic guided vehicle system
  • Pick & Place transfer units
  • Linear gantry robots with various gripper systems
  • Tailor-made solutions for charging kilns

 

Processes

Thermal processes are multifarious and often place high demands on the furnace system and the related process engineering. Especially in the case of high-quality products, for which reproducibility of the process parameters must be ensured, it is indispensable that the parameters in terms of atmospheres and temperatures remain stable. Eisenmann provides the optimum solution for any challenge.

Understanding processes

It is our objective to render complex processes controllable. Our process engineers analyze your specifications and discuss possible solutions with you. If required, they will gather process-relevant data of your existing plants or conduct supporting tests in our technology center.

Among others, Eisenmann covers the following processes:

  • Debindering
  • Pyrolysis
  • Carbon combustion
  • Nitration
  • Carbonization
  • Carbonitriding
  • Siliconizing
  • Sintering
  • Hydrogen sintering
  • Vacuum sintering
  • and many more

We focus on implementing the requirement solutions devised on a laboratory scale on production level. Especially with continuously operating furnace processes, the implementation of different atmospheric conditions at a maximum temperature homogeneity requires comprehensive know-how. Whether heating concept, gas supplying concept, furnace gas-flow system, conveyor concept or lock system – we are familiar with the advantages and disadvantages of the possible solutions and compile the combination that fits you.

Implementing processes

Sometimes very different process steps are implemented within one continuously operating furnace system, e.g. the annealing of thin film photovoltaic layers in an inert atmosphere. We have also developed different systems to be able to separate process zones in one unit. Read more on this topic in Furnaces Types. Please also refer to the different process combinations in powder metallurgy.

 

Electronic Parts

The range of electronic elements in use is comprehensive. So are the answers of Eisenmann Thermal Solutions. For multi layer varistors or ferrites, oxygen sensors or piezoelements. A detailed analysis of the requirements is the essential starting point for Eisenmann in order to offer tailor-made factories for debindering and sintering.

Example:

A series of lift bottom furnaces has been delievered for a well known producer of oxygen sensors. An outstanding solution: the chamber furnace is operated with recirculation air during the debindering process in order to grant a fast and gentle release of organics from the product. Above 600 °C, the chamber is closed and sintering of the ceramic is proceeded by use of ceramic heating elements.

Loading of the furnace from below offers the advantage of an outstanding furnace sealing. Furthermore it provides for the use of a common loading gantry to serve a series of furnaces positioned in a line. The furnace base will be removed to exchange a set of ceramic product carriers with sintered product against a set with fresh product. In no time, the furnace can be charged and restarted.

But it is not only the change over time that is granted by the concept. It is rather the energy which is stored in the furnace and its base which can be recovered by means of the quick restart. Above this, Eisenmann has optimized other areas of system like the exhaust purification. Waste gas from the thermal oxidizer is used to preheat the fresh air which is provided to the furnace during debindering.

Filter & Membranes

Filters and membranes are used as water or fluid filters, exhaust filters or catalyst supports. If based on ceramics, those products can be easily adjusted to offer perfect properties for the requirements of their use.

Contact

Name

Monika  Kunzmann

Firm

Eisenmann Thermal Solutions GmbH & Co. KG

Telephone

work T
+49 7031 78-2177
fax F
+49 7031 78-222177

© 2017 EISENMANN SE