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Views: 2 Author: Site Editor Publish Time: 2026-09-16 Origin: Site
Billet heating is one of the most energy-intensive steps in the aluminum extrusion process, second only to raw material production. The quality of heating directly determines extrusion speed, profile surface finish, and die life. EPS Aluminum's energy-saving billet heating furnace addresses this critical stage with direct-fired spray heating technology, achieving ±5°C temperature control accuracy across multiple independent heating zones. Operating on LPG or natural gas, this system delivers uniform heat distribution for aluminum extrusion billet preheating while reducing fuel consumption by up to 15–20% compared to conventional billet heating equipment.
Unlike traditional gas conduction furnaces that rely primarily on convection and radiation, the direct-fired spray heating furnace utilizes a burner-and-mixer combustion system that injects high-velocity flame directly onto the billet surface. This approach eliminates the cold spots and thermal gradients commonly associated with indirect heating methods.
The combustion system operates at 5–8 kPa gas pressure, adjustable via a pressure reducing valve, with fuel and combustion air combined through a dedicated mixer before ignition. The direct flame impingement accelerates heat transfer to the billet surface, enabling faster heating cycles while maintaining uniform temperature distribution throughout the billet cross-section. This is particularly important for isothermal extrusion processes, where precise temperature profiling along the billet length determines whether the aluminum reaches the die at optimal flow stress.
The furnace features multiple independent heating zones, each equipped with real-time temperature sensors for continuous thermal management. With ±5°C accuracy across all zones, the system provides the thermal consistency required for isothermal aluminum extrusion—a process where billet temperature is carefully controlled to maintain uniform metal flow through the die.
Isothermal extrusion demands a precise temperature taper along the billet length: the leading end (which reaches the die first) should be slightly cooler than the trailing end, compensating for the heat generated by friction and deformation during extrusion. Without this taper, the aluminum can overheat at the die, forcing the press to reduce extrusion velocity and sacrificing productivity. The multi-zone architecture of EPS Aluminum's furnace enables operators to establish and maintain this temperature profile with confidence.
The furnace integrates a fully PLC-controlled system with one-key automatic shearing at the furnace exit. This automation significantly reduces operator workload while ensuring consistent billet temperature from the furnace to the extrusion press. The hot shear acts as the critical connecting device between the heating furnace and the extrusion press, transferring the heated billet from the furnace to the shear roller bed for precise length cutting before entering the press.
This integrated shearing function minimizes the time between heating and extrusion—a critical factor in maintaining billet temperature consistency. In manual operations, delays between heating and pressing allow surface heat loss, resulting in temperature gradients that degrade extrusion quality. Automated shearing eliminates this variability.
The low-fuel-consumption architecture of this billet heating furnace directly addresses the extrusion industry's growing emphasis on energy efficiency. While gas-fired furnaces remain the industry standard due to their simplicity and relatively low upfront costs, increasing pressure to reduce emissions and optimize energy consumption has driven demand for more efficient heating solutions.
The 15–20% energy saving achieved by this furnace translates directly to reduced operating costs. For extrusion plants running continuous production, fuel consumption represents a substantial portion of per-ton conversion costs. Optimizing this single process step creates measurable financial impact across annual production volumes.
Parameter | Specification |
|---|---|
Furnace Type | Direct-fired spray heating furnace for aluminum billets |
Fuel Type | LPG / Natural gas (dual-fuel options available) |
Gas Pressure | 5–8 kPa (adjustable via pressure reducing valve) |
Combustion System | Burner + dedicated mixer for fuel-air mixture |
Heating Zones | Multi-zone independent control with real-time temperature sensors |
Temperature Control Accuracy | ±5°C |
Control System | PLC automated control with one-key auto shearing |
Aluminum Billet Diameter | Customizable per extrusion line requirements |
Energy Saving | Up to 15–20% vs. conventional billet heating equipment |
EPS Aluminum provides flexible OEM/ODM services, allowing furnace size, specifications, and automation levels to be tailored to existing extrusion line configurations. Standard delivery is 45–60 days for heating furnace units, with small-sized machines available in 30 days and complete production lines in 3–6 months. The equipment interface is designed for straightforward operation and maintenance, minimizing training requirements for production staff.
For extrusion operations seeking to improve thermal consistency, reduce fuel costs, and automate the critical billet heating and shearing stage, the direct-fired spray heating furnace represents a technically sound and economically justified investment. Contact EPS Aluminum for a tailored quotation based on your extrusion line specifications and production requirements.
