An 11m 3 oil-vehicle type annealing furnace of a factory with an effective length of 3900mm×2100mm×1400mm is mainly used for heat treatment of steel parts of pumping units. It has been used for fifteen years. Due to the early construction time, it was designed by the time and materials. The limitation is that the furnace wall is made of heavy high-alumina refractory bricks. The top of the furnace is suspended by heavy-duty high-alumina refractory bricks. There is no insulation layer in the design. The combustion system is a direct-injection burner, and the ventilation system is incomplete. Insufficient pressure in the furnace, which forms defects such as increased energy consumption, fast heat dissipation, slow heat storage, black smoke, incomplete combustion, and severe heat loss, resulting in low energy utilization rate of the annealing furnace and pollution to the surrounding environment. The fuel is wasted, the heating time is long, and the furnace body is easily damaged. Since the modification is required to be completed in a medium repair period, the structure of the furnace cannot be changed greatly, so the high temperature resistant aluminum silicate ceramic refractory fiber folding block and the new fuel spray combustion technology are adopted.
The original furnace panel and the shell plates on both sides of the burner are removed, and are welded and reinforced with δ=30mm, δ=8mm steel plate A3, and L100mm×L100mm×10mm angle steel.
The original furnace lining heavy high-alumina refractory brick was removed, and the new energy-saving and high-temperature resistant aluminum silicate ceramic refractory fiber folding block was used to weld and fix the folded fiber on the furnace wall. The folded block has anti-oxidation, heat storage, good heat preservation and heat loss. Less, easy maintenance and other advantages, compared with refractory lining energy saving 20% ​​~ 30%.
The original top heavy-duty high-alumina refractory bricks and angle steel were removed, and the "V"-shaped channel steel body made of A3 steel plate with δ=5mm was welded into an arc top, and six longitudinal reinforcing beams were added at the top (using L70mm×L70mm×7mm angle steel) ), with the furnace panel, the top plate, the spot welding around the furnace body to increase the strength, effectively preventing the top of the furnace lining down after installation. The top is made of a new energy-saving and high-temperature resistant aluminum silicate ceramic folding block.
The original trolley furnace bell seal body was removed, two sand seals were added to the trolley body, and the A3 steel plate with δ=14mm and the angle steel welding material were welded. The trolley body was made of special high-aluminum brick masonry. Whenever possible, reduce the gap with the furnace body.
The reinforced furnace door is reinforced with L100mm×L100mm×10mm angle steel around the furnace door. The new energy-saving and high-temperature resistant aluminum silicate ceramic fiber folding block is installed in the furnace door. When installing, the folding block will be covered with 100mm around the corner of the furnace door. After the door body slides down along the guide wheel by its own weight, it is pressed with the furnace panel to form a good seal, which effectively prevents heat dissipation.
In the reform of the combustion system pipeline, due to the aging of the pipeline for a long time, the air pressure in the furnace is insufficient, so the pipeline is re-arranged, the oil metal hose, the gas supply metal hose, the fuel regulating valve, the air compressor are added, and the compressed air pipeline system is added. The new fuel spray burner has pressure atomization combined with high-pressure internal mixing and atomization to make the fuel atomized particles fine, and can achieve optimal end-flow mixing with combustion air to achieve efficient combustion. It is not easy to block, no coking, the length shape and temperature of the flame are easy to control, the combustion is complete, and no black smoke is emitted. The furnace passed the prescribed oven process and monitored by a one-month production practice, indicating that the transformation was very successful, meeting or exceeding the requirements of the design and transformation indicators.
(1) Increased production and improved product quality. After the transformation, the furnace has good heat preservation performance, fast heating time, short processing cycle, increased production, and the temperature difference in the furnace is greatly reduced, and the product quality is reliable.
(2) Reduced costs. When the original furnace is charged at 5t, it takes 7h to raise the temperature to 850°C, and the fuel consumption is 64.5kg/h. Now it takes only 5h to raise the temperature to 850°C under the same conditions. The fuel consumption is 48kg/h, which shows that the heating time is shortened by 2h. , fuel saving 129kg. During the heating period, the new furnace saves 16.5kg/h compared with the original furnace, and the furnace can save 82.5kg per 5h, so that the total fuel can be 211.5kg (129kg+82.5kg) per furnace. The overall efficiency has increased significantly. It can be seen that the fuel economy benefits are very significant.
The original furnace panel and the shell plates on both sides of the burner are removed, and are welded and reinforced with δ=30mm, δ=8mm steel plate A3, and L100mm×L100mm×10mm angle steel.
The original furnace lining heavy high-alumina refractory brick was removed, and the new energy-saving and high-temperature resistant aluminum silicate ceramic refractory fiber folding block was used to weld and fix the folded fiber on the furnace wall. The folded block has anti-oxidation, heat storage, good heat preservation and heat loss. Less, easy maintenance and other advantages, compared with refractory lining energy saving 20% ​​~ 30%.
The original top heavy-duty high-alumina refractory bricks and angle steel were removed, and the "V"-shaped channel steel body made of A3 steel plate with δ=5mm was welded into an arc top, and six longitudinal reinforcing beams were added at the top (using L70mm×L70mm×7mm angle steel) ), with the furnace panel, the top plate, the spot welding around the furnace body to increase the strength, effectively preventing the top of the furnace lining down after installation. The top is made of a new energy-saving and high-temperature resistant aluminum silicate ceramic folding block.
The original trolley furnace bell seal body was removed, two sand seals were added to the trolley body, and the A3 steel plate with δ=14mm and the angle steel welding material were welded. The trolley body was made of special high-aluminum brick masonry. Whenever possible, reduce the gap with the furnace body.
The reinforced furnace door is reinforced with L100mm×L100mm×10mm angle steel around the furnace door. The new energy-saving and high-temperature resistant aluminum silicate ceramic fiber folding block is installed in the furnace door. When installing, the folding block will be covered with 100mm around the corner of the furnace door. After the door body slides down along the guide wheel by its own weight, it is pressed with the furnace panel to form a good seal, which effectively prevents heat dissipation.
In the reform of the combustion system pipeline, due to the aging of the pipeline for a long time, the air pressure in the furnace is insufficient, so the pipeline is re-arranged, the oil metal hose, the gas supply metal hose, the fuel regulating valve, the air compressor are added, and the compressed air pipeline system is added. The new fuel spray burner has pressure atomization combined with high-pressure internal mixing and atomization to make the fuel atomized particles fine, and can achieve optimal end-flow mixing with combustion air to achieve efficient combustion. It is not easy to block, no coking, the length shape and temperature of the flame are easy to control, the combustion is complete, and no black smoke is emitted. The furnace passed the prescribed oven process and monitored by a one-month production practice, indicating that the transformation was very successful, meeting or exceeding the requirements of the design and transformation indicators.
(1) Increased production and improved product quality. After the transformation, the furnace has good heat preservation performance, fast heating time, short processing cycle, increased production, and the temperature difference in the furnace is greatly reduced, and the product quality is reliable.
(2) Reduced costs. When the original furnace is charged at 5t, it takes 7h to raise the temperature to 850°C, and the fuel consumption is 64.5kg/h. Now it takes only 5h to raise the temperature to 850°C under the same conditions. The fuel consumption is 48kg/h, which shows that the heating time is shortened by 2h. , fuel saving 129kg. During the heating period, the new furnace saves 16.5kg/h compared with the original furnace, and the furnace can save 82.5kg per 5h, so that the total fuel can be 211.5kg (129kg+82.5kg) per furnace. The overall efficiency has increased significantly. It can be seen that the fuel economy benefits are very significant.
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