Renewed Reheating Revolution

Tenova’s contract with Wieland Rolled Products North America initiates a significant upgrade in copper alloy production across the United States. The centrepiece is a Reheating Walking Hearth Furnace capable of handling up to 110 metric tons per hour. It integrates a natural gas combustion system featuring TR Flat Flame Roof burners, an integrated recuperator & a post-combustor module. Coupled with a Selective Catalytic Reduction DeNOx system, Tenova promises up to 90% reduction in NOₓ emissions. “This project integrates advanced combustion & fume treatment technologies to meet both performance & environmental targets,” said Francesco Memoli, Tenova Inc. President & CEO. The installation will enhance premium copper production to support electric vehicle infrastructure & renewable energy industries.

Meticulous Metallurgical Modernisation

The furnace’s natural gas burners and post-combustor deliver elevated thermal efficiency, while SCR DeNOₓ ensures ultra-low emissions. Delivering 90% NOₓ reduction exemplifies the furnace’s environmental credentials. Such technological synergy enables efficient reheating of copper billets or slabs before rolling, simultaneously meeting both productivity benchmarks and emission regulations. “We tailor heat treatment solutions to the unique requirements of non-ferrous production,” said Memoli. The system consolidates Tenova’s leadership within green metallurgy.

Strategic Site Strengthening

The new furnace forms a core part of Wieland’s East Alton modernization plan, which also includes a hot rolling mill for copper alloy components used in electric vehicles, infrastructure, and renewable systems. “We are pleased to continue our collaboration with Tenova as we enter the next phases of this expansion project,” said Greg Keown, President of Wieland Rolling & Recycling. The furnace’s design aligns with broader objectives: boosting production resilience, enhancing sustainability & meeting rising demand in critical sectors.

Environmental Emission Excellence

Reduction of NOₓ by 90% is a transformative shift for U.S. copper production, helping Wieland meet stricter air emission standards under Clean Air Act guidelines. The furnace’s combustion system, with burners & recuperator, recovers heat from exhaust gases, boosting thermal efficiency while reducing fuel usage. This innovation reflects Tenova’s commitment to decarbonizing non-ferrous metallurgy.

Efficiency via Engineered Excellence

Operating at full capacity, the furnace will process 110 metric tons every hour, nearly 2,640 metric tons per day, enabling continuous production cycles. The design ensures precise thermal profiling before rolling, critical for attaining metallurgical targets in ductility & tensile strength. This will support manufacturers creating heat-exchanger tubes, electrical wiring, & EV components, where material consistency is vital.

Collaborative Compliance Cadence

The project underscores the longstanding relationship between Tenova Italimpianti & Wieland. From furnace fabrication to system commissioning, Tenova will oversee full project management, ensuring integration of reheating hardware, DeNOₓ systems & automation controls. This collaboration signals confidence in Tenova’s expertise within non-ferrous sectors.

Strategic Sustainability Synchrony

Wieland’s investment echoes broader sustainability trends in metals manufacturing. By coupling efficient burners, recuperation, post-combustion & SCR DeNOₓ, the furnace supports lower CO₂ & NOₓ emissions. It aligns with corporate ESG targets and federal criteria for industrial emissions reduction programs.

Future-Focused Foundry Framework

Beyond the furnace itself, the project positions Wieland’s East Alton site for future expansions in copper alloy rolling. The furnace’s modular infrastructure allows for additional heat-treatment lines or variant alloys to be processed. Combined with their planned hot rolling mill, the system offers resilience to market shifts in electric transportation & energy systems.

Key Takeaways

• Tenova will supply a 110 t/h Reheating Walking Hearth Furnace plus SCR DeNOₓ system to Wieland’s East Alton plant, cutting NOₓ emissions by 90%.

• The furnace integrates advanced combustion, heat recovery & automation to boost premium copper alloy production for EV & renewable sectors.

• Wieland’s modernization reflects a strategic pivot to sustainability, emission compliance, & enhanced productivity in U.S. non-ferrous metallurgy.