Abstract : The energy-saving technical transformation of gas well treatment furnace is introduced in detail. Practice shows that the technical reform effectively improves the heat rate of the gas well type heat treatment furnace, improves the output of the furnace, and achieves the purpose of energy saving and environmental pollution reduction.
Key words : well type furnace; refractory fiber; energy saving
1 Introduction
The gas well type heat treatment furnace is a heat treatment equipment for long shaft parts and rods. The condition of the equipment itself will directly affect the final product quality, equipment production efficiency, production cost and environmental pollution.
According to the quality requirements of the heat treatment products, the temperature and atmosphere uniformity in the entire furnace must be within the specified range of product quality or heat treatment process requirements, in order to ensure that the quality of the heat treatment product meets the specified technical quality indicators.
Due to the defects of the original furnace itself, uneven furnace temperature, high energy consumption, low production efficiency and poor product quality, it is decided to carry out energy-saving technical transformation of the furnace for these problems.
2 Original furnace condition and main technical parameters
(1) The original furnace is made of heavy refractory brick + diatomite brick, which results in slow heating rate, high temperature on the outer surface of the furnace wall, large heat loss, poor heat insulation, large heat storage, low production efficiency and serious pollution. In the production operation, the temperature in the furnace is often uneven. The uniformity of the furnace temperature exceeds the temperature difference of 10 °C specified by the heat treatment process. The atmosphere is not easy to control, the product rejection rate is high, the combustion process cannot be controlled automatically, and the technical specifications of the heat treatment process are difficult to guarantee.
(2) Main technical parameters of the furnace Heated steel: General carbon steel Studio volume: φ2 300 × 2 550mm Steelware furnace temperature: 20°C Steelware temperature: 850°C Maximum heating temperature: 900°C Maximum load: 4000kg/ Secondary fuel type: natural gas furnace wall surface temperature: 85 ° C
3 Characteristics of the furnace after technical transformation
According to the production characteristics and requirements of the enterprise, the furnace after the technical transformation must improve production efficiency, save energy and reduce environmental pollution, and meet the requirements of heat treatment process.
3.1 Furnace lining structure
The lining after the technical transformation adopts aluminum silicate fiber 130mm+rock wool 60mm structure, and its advantages are:
(1) Aluminosilicate fiber + rock wool structure, good thermal insulation performance, low heat storage loss, and short heating time of furnace;
(2) The aluminum silicate fiber is light in weight, and the thickness of the lining can be reduced. After the technical transformation, the effective volume of the furnace is expanded by 25%, saving steel and reducing the weight of the furnace;
(3) The aluminum silicate fiber furnace village has good thermal stability, and the furnace lining and the furnace body are not easily deformed, which improves the operating life of the furnace;
(4) The cost of furnaces using aluminum silicate fiber lining can be reduced by 20%;
(5) In order to improve the anti-scour performance of the lining, a layer of high-temperature paint is sprayed on the high-temperature surface of the contact flame, which can improve the radiation heat transfer effect and resist the erosion of the high-speed airflow;
(6) The lining fixing device adopts a special structure for preventing metal parts from forming a thermal bridge, thereby reducing heat loss;
(7) According to the actual situation of the site and the convenient construction, the furnace lining is layered.
4 burning device
After analysis and comparison, it is decided to use a fully automatic gas burner, which consists of a gas nozzle, a fan, an igniter and a flame monitor. The characteristics of the burner are:
(1) The burner is equipped with an automatic ignition and flame monitor, which can be matched with the control system to realize automatic control;
(2) The high-speed flue gas flow has greater kinetic energy, and the burner installation position is repeatedly explored and specially designed, which is beneficial to the flue gas circulation and improves the uniformity of the furnace temperature and atmosphere;
(3) The high-speed airflow enhances the convective heat transfer of the workpiece in the furnace, reducing heating time and increasing productivity.
5 automatic control system
5.1 Combustion system The furnace adopts 4 sets of fully automatic gas burners, which are arranged in two groups. Each burner is equipped with an automatic igniter and a flame monitor, which is automatically and continuously controlled by the temperature control system.
5.2 Temperature Control System Each temperature zone adopts intelligent temperature regulation control instrument for continuous inspection and temperature control. Each instrument can set the process curve, the operation is simple and convenient, the heating rate and temperature can be adjusted online, and there are fault alarm and flameout alarm.
5.3 Detection and electronic control Gas pressure detection, digital display and rapid cut-off; furnace pressure detection and adjustment; furnace lid lifting, pressure switch, flame detection and alarm and other chain control.
6 Comparison of main technical indicators before and after technical transformation
After the technical transformation, after commissioning and operation, all technical and economic indicators have reached the design requirements. The main technical indicators before and after the technical transformation are shown in Table 1.
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