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Company Name: Jinan Weiguang Energy Saving Technology Co., Ltd.

Phone: 0531-87565889

Email: huanbaoyaolu@163.com

Address: No.799 Songzhuang Industrial Park, Huaiyin District, Jinan City

Website: dar11.com

Regenerative melting furnace

Regenerative melting furnace

蓄热式熔化炉
  • Category: Regenerative melting furnace

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  • Release Date: 2018/09/01
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Detailed introduction

Brief Introduction of Regenerative Aluminum Melting Furnace

Jinan Weiguang Energy-saving Technology Co., Ltd. is a solid secondary aluminum melting furnace and thermal insulation that integrates the core technology of regenerative combustion and possesses a number of proprietary technologies. It integrates scientific research and design, processing and manufacturing, construction and installation, commissioning and maintenance, and technical transformation. The company specializes in furnace manufacturing. The company focuses on regenerative aluminum melting furnaces and heat preservation furnaces in the recycled aluminum industry. It has accumulated rich experience in long-term research and development and practice. It has designed and manufactured furnaces with a long service life and fully considered the sealing of various parts of the furnace. , Details such as the expansion of refractory materials, the configuration and optimization of furnace materials, all furnaces ensure advanced efficiency and energy saving, and the energy consumption index is better than the national special industrial furnace standards, and has beautiful appearance, ruggedness, stable performance, and fully automatic operation. The price is far lower than the imported products, and has a very high price-performance ratio.

The regenerative combustion automatic control system can flexibly set various thermal parameters of the kiln through the touch screen, and the advanced industrial control computer PLC automatically realizes the automatic flame detection, automatic flameout protection, low-pressure safety cut-off, ignition program control, pulse control during the combustion process. Combustion control, commutation control, automatic temperature control, flow pressure control, firing atmosphere control and other control programs. Once a safety abnormality is found, the operating software will immediately start an alarm signal to prompt the operator to deal with it.

The graphical interface of the control system is rich and intuitive, including real-time furnace condition detection interface, manual / automatic control operation interface, process parameter setting interface, alarm parameter setting interface, historical temperature query interface, alarm information summary interface and so on. The operating system can provide four monitoring operation modes: automatic, semi-automatic, manual, and no-load, in order to meet the needs of various working conditions or process adjustments, equipment maintenance and so on. Regenerative combustion automatic control system has reliable operation and simple maintenance. It is currently a popular "fool" operating system in the world.

Regenerative high-temperature air combustion technology, the transformation of aluminum melting furnaces and heat preservation furnaces, not only can overcome the shortcomings of conventional aluminum melting furnaces, but also can achieve economic and social benefits of energy saving, environmental protection, and increased production. Extremely important.

Working principle of regenerative combustion

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As shown in the figure above, two A / B regenerative burners are arranged in pairs outside the furnace, and the interior is filled with ceramic heat storage balls with thermal energy transmission and strong storage power. When the A burner burns, the PLC automatic control system controls four The on / off valve switches the air / smoke flow direction and the natural gas AB burner solenoid valve switch. Air at normal temperature is driven by a blower. It enters the A burner heat storage tank through the four-way reversing valve and is heated by the heat storage body in a very short time. When the temperature of the furnace is approached, the flue gas in the coiled furnace forms an oxygen-depleted high-temperature gas stream with an oxygen content of about 8%. At the same time, the natural gas valve A is opened to inject fuel into it, and the fuel is fully burned in this state; When the burning high-temperature flue gas in the furnace passes through the B burner, the heat is stored by the heat storage body in the heat storage pool, and the low-temperature flue gas is discharged out of the furnace through the four-way reversing valve; the PLC setting program takes 30 to 90 seconds The frequency is reciprocated, so as to save energy and reduce NOx emissions.

蓄热式熔化炉 

Our company designs and builds various types of rectangular or circular gas-storage type high-efficiency energy-saving aluminum melting furnaces and heat preservation furnaces, which are composed of furnace lining refractory materials, furnace body steel structure, furnace door and furnace door lifting mechanism, aluminum water flow channel, Composed of equipment such as regenerative combustion system and its automatic control system, this set of equipment has the following technical advantages:

◆ It is suitable for newly built aluminum melting furnaces and heat preservation furnaces, as well as for the regenerative technological transformation of old kiln furnaces, which can keep the original furnace foundation and steel structure intact, and add regenerative burners on both sides or the same side of the old furnace for construction. Simple, advanced and mature technology.

—85 天然气/吨铝以内,节能效益突出,节约燃料消耗高达30%—70%,运行成本低廉。 ◆ The preheating temperature of the combustion air is about 1000 ℃, and the unit consumption index of the molten fuel is within 50m³ -85 m³ of natural gas / ton of aluminum, which has outstanding energy saving benefits, saves fuel consumption by up to 30% -70%, and has low operating costs. After the project is implemented, only the energy-saving benefits can recover the project investment within half a year.

◆ The flue gas is completely discharged from the heat storage body, and the exhaust temperature of the flue gas is lower than 120 ℃ -150 ℃, so that the ultimate recovery of the flue gas waste heat can be achieved, and the waste heat recovery rate can reach 80% -90%, so no auxiliary flue design is needed, Exhaust smoke from high chimneys reduces project cost.

◆ Fast heating speed can increase the output of aluminum melting furnace of the same size by about 20%.

◆ Organic stratified oxygen-depleted combustion extends the flame combustion area up to the furnace boundary to make the temperature distribution in the furnace uniform and the heating of the waste aluminum more uniform, which reduces the local high temperature and the oxygen-enriched environment's oxidation of the waste aluminum. The burning loss rate of aluminum metal was reduced from 2% to 3% to less than 0.8%, which greatly improved the economic benefits of customers.

NOx 的排放,远低于国家允许排放标准,确保浓度在100ppm以下。 ◆ The NOx emission in the flue gas is greatly reduced , which is far lower than the national allowable emission standard, and the concentration is guaranteed to be below 100ppm.

◆ The project has a high degree of automation. The entire combustion process can be controlled by an intelligent temperature controller or a flexible PLC to control Xiyong to achieve full automatic control, including automatic ignition, automatic adjustment of furnace pressure, automatic high / low fire operation, automatic flame detection, System automatic detection, flameout automatic protection, safety automatic protection, etc.

◆ The project investment is small, the energy saving benefits are significant, and the project investment recovery period is short, ensuring that the energy conservation investment is recovered within six months.

蓄热式熔化炉 

Our company can professionally design and manufacture regenerative systems, aluminum melting furnaces and holding furnaces that meet the site installation conditions according to the parameters of aluminum melting furnaces and holding furnaces provided by customers. According to the actual needs of customers, the furnace lining refractory can choose high-quality high-aluminum refractory bricks, or high-strength low-cement castables and high-quality thermal insulation materials. Extend the service life of aluminum melting furnace. The furnace roof can be designed as a flat roof structure or a vault structure. The following furnace lining refractory materials are configured as two typical vaulted square door furnaces:

 

Refractory configuration scheme one

Refractory configuration scheme two

Hearth: total thickness 650mm

Al2O3 抗渗高铝砖 230mm 70% Al2O3 impervious high alumina brick

150mm impervious refractory castable

270mm high-quality thermal insulation brick

10mm welded hearth Q235 steel plate

140mm 14 # International Channel Welded Wire Mesh

Hearth: total thickness 650mm

230mm non-stick aluminum high-strength castable

150mm impervious refractory castable

200mm high-quality thermal insulation brick

10mm welded hearth Q235 steel plate

160mm 16 # International Channel Welded Wire Mesh

Furnace wall below the level of aluminum: total thickness 600mm

Al2O3 高铝砖 230mm 70% Al2O3 high alumina brick

345mm high quality insulation brick

25mm aluminum silicate fiber blanket

Furnace wall below the level of aluminum: total thickness 600mm

350mm non-stick aluminum high-strength castable

230mm high-quality thermal insulation brick

20mm aluminum silicate fiber blanket

Furnace wall above the liquid level of aluminum: total thickness 600mm

230mm heavy refractory brick or Grade III high alumina brick

345mm high quality insulation brick

25mm aluminum silicate fiber blanket

Furnace wall above the liquid level of aluminum: total thickness 600mm

350mm low cement castable

230mm high-quality thermal insulation brick

20mm aluminum silicate fiber blanket

Arched / flat furnace roof: total thickness 500mm

Al2O3 高铝砖 230mm 60% Al2O3 high alumina brick

50mm high alumina cement mortar

100mm aluminum silicate fiber blanket

120mm lightweight insulation castable

Arched / flat furnace roof: total thickness 500mm

300mm high quality low cement refractory castable

100mm aluminum silicate cotton fiber blanket

100mm lightweight insulation castable

All-fiber stove top has better energy saving effect

Furnace door: total thickness 300mm

200mm low cement high strength refractory castable

100mm ceramic fiber blanket with stainless steel anchor hook

Furnace door: total thickness 300mm

200mm low cement high strength refractory castable

100mm ceramic fiber blanket with stainless steel anchor hook

Slag thickness of furnace door slag ≥ total thickness of furnace bottom

Furnace door slope length 1200mm: high density wear-resistant high alumina brick

Furnace saddle width 300mm: high density wear-resistant high alumina brick

Slag thickness of furnace door slag ≥ total thickness of furnace bottom

Furnace door slope length 1200mm: steel fiber reinforced castable

Furnace saddle width 300mm: steel fiber reinforced castable

Furnace door thickness 350mm: steel fiber reinforced castable

Furnace door thickness 350mm: steel fiber reinforced castable

Burner mouth: total thickness 600mm

600mm high aluminum zirconium-containing low cement refractory castable

Burner mouth: total thickness 600mm

600mm high aluminum zirconium-containing low cement refractory castable

Auxiliary flue: none

Auxiliary flue: none

The steel structure of the furnace body of the melting furnace and the holding furnace uses 14 # channel steel as the skeleton, and the 8mm thick Q235 steel plate is used as the furnace surface. After welding to each other, a rigid whole with good sealing effect and low heat loss is used. Peripheral steel frame structure. The bottom of the furnace adopts 14 # I-shaped steel and 14 # channel steel as the frame, and the frame is sealed with a 10mm thick Q235 steel plate.

The furnace bottom is equipped with a permanent magnetic stirrer. The steel structure of the furnace bottom must be designed according to the requirement of aluminum-water permanent magnetic stirring. A 20mm thick non-magnetic stainless steel skylight is added, and reinforcement ribs are welded. The thickness of the entire furnace bottom is less than 500mm. It is required to take into consideration both the strength of the furnace bottom and the insulation performance to prevent the penetration of aluminum water.

The furnace door shell is made of 16 # channel steel and 16mm thick Q235 steel plate welded into a solid frame structure, lined with light refractory insulation material, and fixed with anchor hooks to achieve good thermal insulation, light weight and firmness. The furnace door can be made into a cable-stayed furnace door or a vertical lifting form. The furnace door and furnace mouth are sealed with a track-type self-weight pressing mechanism and a refractory fiber rope soft edge sealing device, which has the characteristics of long service life and good sealing effect, and can effectively prevent the heat from leaking out of the furnace. Equipped with a counterweight, the furnace door is automatically controlled by the control cabinet panel, and the furnace door lifting speed is 6-8m / min.

Each furnace is equipped with one or two molten aluminum drains and a set of molten aluminum flow channels for transferring molten aluminum to the casting machine. After scientific calculation and practical experience, the position of the nozzle is reasonably arranged, and special design is adopted to effectively prevent the aluminum water from blocking and freezing at the nozzle, avoiding delay in production and causing injury to the operator.

 

Case introduction:

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Wheel and rim melting customers, 15T shift production, smelting Waste can melting customers, 20T shift production, smelting

—90 速度2.5T/h,吨耗气量 80m³ —90 Speed 2T / h, air consumption per ton 80m³ —90 Speed 2.5T / h, air consumption per ton 80m³ —90

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Aluminum ingot smelting customers, 25T per shift, smelting Waste aluminum profile smelting customers, 20T per shift, smelting

以下 速度2.5T/h,吨耗气量75 —85 Speed 3T / h, air consumption per ton below 70lm³ Speed 2.5T / h, air consumption per ton 75 —85

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Waste aluminum smelting customers, 10T per shift, melting speed Waste hubs, cans, melting customers, 25T per shift,

—85 熔炼速度3T/h,吨耗气量85 以下 Degree 1.5T / h, gas consumption per ton 75 —85 Melting speed 3T / h, gas consumption per ton below 85

 


Related tags: regenerative alumina furnace, alumina melting furnace , regenerative alumina furnace price , regenerative alumina furnace wholesale

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