Comparing high volume small batch vacuum heat treating with single chamber vacuum heat treating.

1. 1
SyncroTherm® vs. Single Chamber Vacuum Furnaces
Reciprocating Saw Blade Production Comparison

2. 2
Hardening of HSS saw blades at 2050°F (1120°C)
310 x 12 x 0.6mm, weight: 0.019 kg/piece
annual production:  20 Million/pieces
Single Chamber Vacuum Furnace
24“x24“x36“ (600x600x900mm), 10 bar
weight: net 370 lbs (168 kg), gross 940 lbs (426 kg)
9000 saw blades per workload
SyncroTherm (using 5 Hot Zones)
20“x6“x24“ (500x600x150mm), 6 bar
weight: net 29 lbs (13 kg), gross 40 lbs (18 kg)
700 blades x 13 loads = 9100 blades
Reciprocating Saw Blade Comparison

3. 3
Comparison of production volume
Single Chamber Vacuum
Furnace
Process time: 220 min
per 9000 saw blades
load weight: net 168 kg
(gross 426 kg)
5040 h/yr @ 90% efficiency
capacity: 1.237 loads or
net: 208 tons/yr
gross: 505 tons/yr
SyncroTherm (5 Hot Zones)
Process time: 45 minutes per
700 saw blades
13 loads x 700 blades = 9,100
á 45 min + (13 loads x 9.6 min cycle)
= 170 minutes
load weight: net 13 kg (169 kg)
(gross 18 kg) (234 kg)
5040 h/yr @ 90% efficiency
capacity: 28,953 loads or
net: 379 tons/yr
gross: 521 tons/yr
2nd furnace is required (1.8)
capacity: 2226 loads or
net: 373 tons/yr
gross: 838 tons/yr

4. 4
Parameters for cost calculation
Nitrogen per m³ = $0.1915
Electricity per kWh = $0.2051
Cooling water per m³ = $0.1368 (closed loop)
2, Single Chamber Vacuum Furnaces
Maintenance: $23,250/yr (1 hot zone in 8
years)
Fixture: $6,850/set; lifetime 900 cycles
SyncroTherm
Maintenance: $13,700/yr
Fixture: $685/tablet; lifetime 900 cycles

5. 5
Results annual running cost
• Energy consumption: 480,000 kWh x 1.8* = 864,000 kWh
• Nitrogen: 55,000 m³ x 1.8* = 99,000 m³
• Running cost per year: $143,600 x 1.8* = $258,480
• Cost per kg: $0.684
Single
Chamber
Vacuum
Furnace(s)
• Energy consumption: 415,000 kWh
• Nitrogen: 215,000 m³
• Running cost per year: $166,844
• Cost per kg: $0.4376
SyncroTherm 5
* Factor 1.8 for 2 Single Chamber Vacuum Furnaces

6. 6
53
11
160
91
52
0
61
54
32
32
0
50
100
150
200
250
300
350
400
MonoTherm - 1 load SyncroTherm 5 - 13 loads
Parts
Auxiliaries
Heat up of insulation
Insulation heat loss
Fixture
181 kWh
389 kWh
Distribution of engery for 900 saw blades in kWh
Single Chamber – 1 Load SyncroTherm – 7 Loads

7. 7
Comparison single-chamber vs. multi-chamber systems
J
t
1120°C
20°C
Single chamber furnace: thermochemical process and quenching in one chamber
Multi-chamber system: separate chambers for thermochemical process & quenching (“Treatment
chamber“ (TC) and “Quench chamber“ (QC))
J
t
TC
J
t
QC
1120°C
20°C
250°C
20°C
 No additional energy is consumed to heat and quench the TC; higher throughput

8. 8
Summary
• Enhancing energy efficiency is of great importance
• Optimized thermal insulation and fixtures provides improved energy efficiency
• Small batch sizes can be heat treated in timely manner with high energy efficiency
• SyncroTherm® is dedicated for small and midsize parts, materials e.g. HSS, case
hardening steels, etc.
• Hot zones can be dedicated for heat treatment process e.g. case hardening,
hardening, annealing, tempering, brazing
• SyncroTherm for small or larger series and flexible production of daily business