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Client List
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- TransAmerica Automation (PSI)
- Allegheny Ludlum
- Midland DRAP Line
- Brackenridge
- Bagdad
- Chugai Ro Furnace Co.
- California Steel Industries
- United States Steel
- Mon-Valley
- Gary
- Irvin
- Tamco Steel Company
- Duferco Farrell
- Sterling Steel
- KMI Systems, Inc.
- FLOWLINE
- Wheeling Pittsburgh Steel
- V&M STAR
- Ohio
- Texas
- Johnstown America Corporation
- Elliott Corporation
- Vallourec & Mannesmann
- Ivy Steel & Wire
- MMI Products
- CombusTech LTD.
- Changon Specialty Steel Co., LTD.
- Connecticut Steel Company
- Bloom Engineering Company
- United Foundries, Inc.
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Nucor
Subcontractor to Nucor and Praxair on a DOE funded DOC
"Dilute Oxygen Combustion" Project. Analysis and
justification of the world's first low NOx, high
efficient oxyfuel technology applied to a top and
bottom fired bar mill reheat furnace. Used finite
element mathematical modeling methods w/product
embedded thermocouples to validate real world thermal
gradients and control accuracy. Established base-line
status quo boundary conditions and verified installed
modified acceptance guarantees.
Babcock & Wilcox
Utilizing finite element modeling methods to determine
projected temperature gradients attained while heat
treating complex tube assembles in a huge car bottom
furnace. Project required sophisticated control
technology, critical assembly stacking arrangements,
unique separator designs, and combustion system,
control, and firing approaches that provided enhanced
assembly temperature uniformity.
Kennecott Copper
Used inferential qualitative and simulated finite
element analysis to optimize the firing of a refining
and anode casting holding furnace. Determined if
liquid copper flowing into a 25 ton holding furnace,
at a rate of 48 tph, on interval batch cycles of 12
ton per 15 minutes can be superheated to 150F.
Existing holding furnace was retrofitted w/high
efficient oxyfuel combustion system.
V&M STAR
Performed an extensive Performance and Emissions
Optimization Study on a Vallourec and Mannesmann owned
Mini-Mill. Used sophisticated analytical tools to
define status quo and simulate modified enhanced
conditions. Needed to engineer cost-effective
technologies that met Ohio EPA Title V compliance,
lowered emissions, maximized heating capacity, lowered
energy consumption, increased yield, and improved
product heating quality.(T-PEA™)
United States Steel
Supplied 80" hot strip mill with a necessary
engineering and combustion services to optimize the
performance of five-(5) existing three zone top and
bottom fired recuperative pusher-type slab reheating
furnaces. In addition, performed a thermal audit that
was designed to validate the temperature set points
and resultant fuel/air flows that were controlled
through an existing Level II supervisory control
system. Results included reductions in fuel
consumption, scale formation and improved heating quality.
Titanium Metals Corporation
Established (baseline) status quo conditions for forge
shop ingot reheat furnace complex. Optimize heating
quality of exotic titanium RCS product and reduced
hydrogen pick-up. Constructed detailed testing methods
to gain clear understanding of existing conditions and
simulate enhanced performance scenarios.
Republic Engineered Products
Supplied combustion engineering services for the 9/10"
bar mill walking beam reheat furnace. Analyzed the
existing combustion and control system to determine
the quality of combustion air available for zonal
thermal input. Measured all static and differential
pressures to help understand problems. Determined
areas of excessive pressure drops that limit optimum
combustion, and performed a recuperator efficiency
check that included waste gases through, transient
temperature gradients, and oxygen and combustibles
content. Purpose of project was to optimize reheating
capacity (quality tons produced).
TXI Chaparral - Texas
Developed a multi-dimensional interactive large
section mill finite element near net shape caster mold
model. The proprietary platform encompassed operator
interface screens, operator input/output (manual and
automatic) screens, and included multiple depth
levels (both on wide and narrow faces inclusive). The
model was based on resident in-house knowledge coupled
with extensive on-site real time data
acquisitions (embedded thermocouples). All heat
transfer coefficients, thermal conductivities, thermal
material interface properties were verified based on
real-world values. Pertinent variables included -
cross sectional dimensions (section, mold size,
thickness), plating material (chrome or nickel),
casting speed, metal temperature, wide and narrow face
water temperatures, respective water velocities,
oscillation rate, variables on meniscus level,
metallurgy, and shaving depth. Purpose of the model
developments were to increase mold life (campaigns) and
optimize quality of cast product.
PRAXAIR, Inc.
ALFA has a formal consulting agreement established with Praxair to provide
multiple technical services that include the review and development of marketing
plans; conducting economic analysis for applications that involve oxy-fuel
combustion systems; and preparing, presenting, and participating in
customer-based and in-house technical presentations. ALFA supplies detailed
engineering studies, uses mathematical finite element modeling tools, and
provides analytical and diagnostic services to assist in quantifying the
economic returns gained through applying oxy-fuel technologies.
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