Annealing Oven Technology for Aluminum Cable: How NUTEC Bickley Keeps Networks Energized
Annealing Oven Technology for Aluminum Cable - NUTEC Bickley
March 25, 2025
4 minutes
Discover how NUTEC Bickley designed and installed a customized aluminum cable annealing oven that optimizes thermal uniformity and energy efficiency.
Arturo Arechavaleta – VP Metal Furnaces
NUTEC Bickley has just manufactured and installed an annealing oven, custom designed for processing reel-mounted compact aluminum cable. The client for this contract operates numerous plants across North, Central and South America and has a portfolio of products supplied to organizations involved in the generation, transmission, and distribution of electricity.
Custom Oven Design for Aluminum Cable Heat Treatment
Using a load area of 2.45m wide x 3.73m long x 2.45m high, this oven operates with a single car per cycle and can accommodate a maximum of 8,620kg (total, including the cable, spool and rack). The operating temperature is 345°C. For aluminum cable, the heat ramps up from room temperature to 345°C in a minimum of one hour. There is a variable soaking time, depending on the exact nature of each product batch to be treated.
This natural gas oven features two high-performance package burners. Each burner is equipped with a 310 stainless steel flame protector tube (to avoid flame deformation and high direct flame radiation), individual ignition, a flame failure relay, a flame detector, an ignition transformer, and a locking solenoid valve. There are two temperature control zones, designed to allow a combination of flow patterns in order to generate rapid heating and excellent temperature uniformity. Each zone has a baffle system to help direct the flow of hot air directly to the aluminum cable reels and to return this heated air back to the burners.
Arturo Arechavaleta, NUTEC Bickley’s VP, Metal Furnaces, said: “Our customer is a leading producer of electrical cable, supplying thousands of users in a very demanding market. This is a highly specialized annealing process, and NUTEC Bickley has successfully addressed key design factors such as effective air circulation, temperature uniformity, and custom loading and unloading of heavy spools.”
Efficient Convection Heating for Uniform Annealing
Effective convection heating is achieved via centrifugal recirculation fans that deliver high-volume, controlled air circulation around a horizontal flow pattern, i.e. from the walls towards the center of the oven. A computational fluid dynamics (CFD) simulation was conducted to aid design of the air handling system, resulting in good uniformity. During comprehensive pre-delivery testing – carried out at the NUTEC Bickley facility – the oven’s temperature uniformity was measured at well within ±5°C.
An industrial annealing oven with a horizontal airflow pattern, showcasing centrifugal recirculation fans mounted on the walls. Arrows indicate the controlled air circulation, ensuring even heat distribution. A thermal simulation overlay highlights temperature uniformity, demonstrating a precise ±5°C variation.
Thermal Insulation System for Energy Efficiency
To further maximize the thermal efficiency of this modern annealing oven, an advanced insulation system has been provided. The oven ceiling, walls and door are fully lined to a depth of 15cm with 190kg/m3 density ceramic fiber, fitted as a modular lining system. The ceramic fiber insulation offers low thermal conductivity, low heat storage and loss, thermal shock resistance, and a lightweight, easy to install construction. There is a high temperature limiter, separate from the control equipment, that protects the product from overheating.
A cross-sectional view of an industrial oven, illustrating its 15 cm thick ceramic fiber insulation lining the walls, ceiling, and door. The insulation material is labeled with key benefits such as low thermal conductivity and heat loss. A heat map effect emphasizes the reduced thermal escape, enhancing energy efficiency.
Heavy-Duty Loading System
Car movement is based on a system featuring a gear motor with chain transmission, with a guide configuration for the drag chain and car. This makes for much easier loading and unloading.
The heavy cable spool is rolled into the car, meaning single-point loading or concentrated loading on a single point is possible. The car’s construction is sturdy enough to withstand this. The oven’s vertical lift doors lower and seal automatically once the car with its spool load is in position in the oven, and the same in reverse when the cycle is complete.
Interested in industrial heat treatment solutions for your process?
Arturo Arechavaleta – VP Metal Furnaces
NUTEC Bickley
Carr Saltillo–Monterrey 100 (Km 62.5)
66359 Santa Catarina NL, Mexico
Tel: +52 81 8254 0633
E-mail: arturoarechavaleta@nutec.com
This is Nutec Bickley
Providing Thermal Equipment Solutions that go beyond expectations
We serve multiple industries through the design, building and installation of combustion systems, thermal insulation and highly specialized industrial furnaces, kilns and ovens. We are focused on understanding our customers’ needs and supplying the best equipment at the most competitive price.
In a major, high-value project – the second at this particular plant in Mexico – NUTEC Bickley will supply a 125m-long tunnel kiln to one of the world’s leading advanced ceramics manufacturers.
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