Industrial Batch Ovens
Batch Ovens are a type of furnace or thermal process equipment used in a variety of industrial and laboratory settings. A typical batch oven is an insulated five-sided chamber with a floor that sometimes may also be insulated or feature high temperature concrete flooring. Access to the interior is via product door. The equipment is sized according to the largest substrate that is going to be processed.
Batch ovens are versatile, and excel in large part applications, long duration heating times, and low production flow. Horizon has standard and custom batch oven sizes to fit your ideal production process.
We will design batch ovens for the following applications and more:
- Curing of paints
- Drying of water or other liquids
- Heat Treating
- Sand Core Drying
- Composite Curing
- Powder Paint Curing
- Stress Relieving of various substrates
- Adhesive and Gel Curing
Batch ovens are commonly used in the following industries:
- Heat Exchanger Process Equipment
- Heat Treating
- Carbon Fiber
- 3D Printing
Batch Ovens deliver standard or a customized volume of heated air to the substrate. We can customize the airflow and the heat according to the requirements of the production load. With precise control over the heating and airflow process we maintain consistent temperature control as well as delivering significantly lower operating costs with the highest efficiency ovens in the industry. Utilization of variable frequency drives on all fan motors allows for complete process control via human machine interface systems (HMI). We will custom design any oven, available with temperatures up to 1200 °F, crafted to perfectly fit your production needs. Smart Control allows the operator to monitor, control and change the operating conditions when the product load changes.
With Smart Cyclone Technology™ capabilities and indirect fired heating systems the recirculation air flow can be reversed several times during an oven cycle time for sensitive production processes. Automated through the PLC, combined with prior input for the production requirements, the air recirculation fans will turn in the opposite direction, reversing the airflow through the product. This is a unique capability allowing Horizon to offer customer additional product process capabilities. With the recirculation fans strategically located inside the oven chamber, air can be directed through the product load that otherwise may not be possible with conventional nozzles technology.
Efficiency and Innovation for Batch Ovens
The driving optimizing air flow and temperature of a Cyclone Oven™ is high volume air flow with low pressure. Our technology improves heat transfer to the product, resulting in shorter process times.Shorter process times means shorter ovens reducing overall footprint, saving floor space. The Cost of Operation consists of several factors. Gas: the bigger the oven the more gas is used during heat up. The bigger an oven the more BTU’s required to heat up the entire oven. With the smaller oven, having fewer square feet of wall, results in less wall loss. The walls have been redesigned into larger modular wall sections to retain more of the heat verses traditional panel designed ovens that are offered in the industry. Thicker and heavier insulation in the walls also reduces wall losses and is cooler to the touch for operator safety. The product being processed inside the oven is going to absorb the BTU’s required to complete the process. For custom applications, Horizon will help the customer develop the entire process.
Electricity is the next item for operating costs.In a gas fired industrial oven the one thing that drives the electricity use up is the motors that power the recirculation fans on the oven. The typical conventional industrial oven run at air velocities inside oven from 3000 feet per minute (FPM) to 6000 FPM. These velocities are at the air nozzles.
The theory is to have the velocity inside the supply at approximately half the speed of the nozzle velocity creating a back pressure inside the ductwork. Once the entire duct is pressurized, the air coming out of the nozzles throughout the oven is equal. This is needed to have a uniform air flow in the entire interior of the oven. All this extra pressure increases the motor horsepower(Hp) up on the recirculation fans.
Conventional ovens operating a fan at 18,000 cubic feet per minute (CFM) will require approximately 2 ½ inch to 3 inch of static pressure in order to provide 4000 FPM at each nozzle. This requires a 20 to 25 Hp motor. Horizon Cyclone Oven™ design with the highest velocity air flow is 1,800 FPM. To achieve the same 18,000 CFM will require only ¾ inch to 1 inch of static pressure. This requires only a 5-horsepower motor. This is a savings of 75 to 80% in HP and ultimately kW resulting in significant operating savings over the course of the lifetime of the equipment.
The Cyclone Oven™ design can be applied in applications with process temperature up to 1,200 °F.
- Higher velocity at the product will transfer the heat into the product faster.
- Providing a quicker heat up time.
- Resulting in a smaller oven.
Performance of Conventional vs Cyclone Technology™ Batch Ovens
Temperature Uniformity is a crucial part in the heating process of your product. The main component to control the heat input into the product is the volume of air flow. The more air flow moving inside an oven and the more air changes in an oven, will give you better temperature uniformity. The limit to the air volume is typically the size of the nozzles and the speed. For most applications this limit is 4000 FPM. Once the air leaves the nozzles the velocity drops off very quickly. If 3/8” nozzles are spaced on 12” centers the air velocity will drop to 125 FPM average through the product. With the Cyclone Technology™ design, which does not have supply nozzles at high velocities, allows us to provide more total air compared to a conventional oven. All while doing it with less energy usage.
The other benefit to having more air is that the average velocity of the air past the product is 3-6 times higher than conventional oven designs.
The curve images below visually show thermocouples attached to a product. Conventional Oven temperature curve shows a lot less time at temperature versus the Cyclone Oven™. This product uniformity assures highest possible product quality:
Horizon Industrial Batch Oven Construction & Features
Exterior Construction of the oven is fabricated from 3/16" plate and solidly welded resulting in no heat loss due to air escaping through conventional oven panel seams.The plate construction is 500% thicker than convention oven panel sheet metal. This design meets NFPA guidelines for oven design and fulfills the explosion proof criteria. Durability typically in industrial oven construction is tongue and groove insulated panels. These panels can come in a variety of thicknesses from 2” to 8”. What is more common is the interior and exterior steel of the panels. Whether they are aluminized steel or stainless, the skin thickness is 20-gauge sheet. The panels slide into each other approximately every two feet, creating a seam between every panel.
This seam is a leakage point for heat and any contaminants from the process in the atmosphere inside the oven. Eventually, condensate will drip on the side of the oven through the panel seams. Other vapors, such as from oil, will work through the seams and re-condense on the exterior of the oven. If the vapors are escaping the oven, then the heat is also escaping the oven. With the Horizon design being constructed welded tight, with no open seams, the design will remain clean looking on the outside. Welded tight keeps all the vapors on the inside of the oven, which also contains the heat more efficiently. Oven insulation is designed according to the operating requirements designated by the process. Using a non-settling rockwool industrial grade insulation material the oven wall thickness will vary depending on the maximum heat setting of the oven. Typical design ranges from 4 to 8 inch thickness for operating temperatures up to 1200 ⁰F (649 ⁰C).
All our ovens are fully assembled and tested in our factory. A temperature profile is created via a datapak and confirms all critical design parameters are met prior to shipping.
Modular designs can be incorporated at the beginning of the project to allow for future expansion.
Interior Construction of the oven interior is fabricated with aluminized or stainless-steel sheet metal. The interior shell is constructed of 18 gauge Aluminized or stainless-steel sheet. This is 25% thicker than the typical industrial oven on the market. This construction also reduces the amount of support structure required on the exterior of the oven, further reducing through metals to the outside. The internal return ductwork of the oven brings recirculation air through the burner flame and back to the air recirculation fan. Additionally, the ductwork acts as a radiant heat shield that reflects heat to the product process work area. The radiant affect further enhances the oven chamber uniformity and allows heat to be absorbed by the product and therefore enhances product temperature uniformity, which leads to higher quality products at the lowest cost possible.
- Roof Safety Railings
- Access Ladders
- PLC Controls
- Roll-up Doors under 500 degrees F
- Thermal Oxidizer
- Thermal Oxidizer with Heat Recovery
Industrial Batch Oven Options & Accessories
Below are some of the brands we use for our Torrent Technology™ washers: