Production process of REAZN BELGIUM optimized

22 09 2020 Hafibo

REAZN BELGIUM is part of the REAZN Group, a multinational company based in Kruisem. It specializes in the recovery, recycling and re-industrialization of zinc alloys. The demand for recycled raw materials is constantly increasing and in order to meet this demand REAZN BELGIUM had to optimize its production process. It appealed to Lybover METAL to provide the piping between the burner skid and the furnaces. This is an improvement for the production, for the environment and for the employees.

In today's society, companies and consumers want more and more recycled products. By working with recycled zinc alloys from the REAZN Group can be developed into high-quality products made from recycled materials. In order to recycle zinc from waste streams, REAZN BELGIUM uses melting furnaces. In the past, the furnaces were operated with natural gas and ambient air. But in order to optimize the yield and efficiency of the furnaces and to increase annual production, investments were made in new burners and a burner skid. This allows them to create more heat and better transfer it to the materials in the ovens.

There are six connections per furnace, namely one compressed air line, two natural gas lines and three oxygen lines. The skid takes care of the correct dosage of these gases over the ovens. A total of 720 meters of tested pipes were installed. Between the new tank for storing liquid oxygen and the burner skid, Lybover METAL installed a new stainless steel main line. All pipes were mounted in such a way that the passageways remain free for forklift trucks and other vehicles.

Limited time on site thanks to 3D scanning

In order to make the work run smoothly and efficiently, Lybover METAL carried out a 3D scan of the current production hall. Afterwards, the new burner skid and the piping were drawn into this scan. In this way, REAZN BELGIUM saw the complete end result and was able to make adjustments where necessary. Once the design was fully approved, production started. By using 3D scanning, the activities on site could be kept to a minimum. All pipelines were prefabricated in the Lybover METAL workshop. In this way, the welding work was also carried out in optimal conditions and its quality could be guaranteed. The work on site was rather limited to mechanical assembly. "Where previously all welding had to be carried out on site, we now effectively only had to perform one weld on site. This resulted in an enormous saving of time and a quick conversion," says Dirk Van Canneyt, Project Engineer at Lybover METAL.

Safety and flexibility

As far as safety is concerned, REAZN BELGIUM is at the forefront of its sector. Zinc recycling is not without risk of accidents. REAZN BELGIUM strives to make all operations as safe as possible. The necessary safety systems, including ISO45001, have been put in place and work permits and the associated risk analysis are used to prepare each project. REAZN BELGIUM found the same attention to quality and safety at Lybover METAL. A very tight timing was set. In less than ten days, the pipes between the burner skid and the ovens had to be converted and tested. Due to the presence of ten other companies during the standstill, consultation was crucial. Together with the customer, a safe solution was always sought. "There was perfect integration and Lybover METAL was very flexible right from the start. This was of great value to us", says Production Manager Sven De Puydt, REAZN BELGIUM. "Lybover METAL adhered very well to the safety regulations. Which is not always obvious in a warm and dusty environment".

Advantages new burners and burner skid

  • For the employees there is 5 to 10 dba less noise nuisance. The new system only works with an oxygen flow and not with fans.
  • From an environmental point of view, energy consumption has been reduced. There is less heat loss, resulting in better heat transfer and a lower temperature in the production hall. There is virtually no formation of NOX compounds, because there is no nitrogen present in the ovens.
  • There is also a major improvement in terms of production technology. The cycle time has been shortened, as a result of which more zinc can be recycled in the shorter term.