The 24-line electric heating heat treatment furnace (4) of our company's pilot plant has been used for many years. In addition to the long-term disrepair and poor insulation performance, there are some shortcomings in the structure of the furnace itself, which makes it difficult to meet the high-quality products. Quality requirements for heat treatment processes. In order to improve the thermal efficiency of the heat treatment furnace, reduce energy consumption, and also to better meet the process requirements, we have implemented an overall transformation of the heat treatment furnace.
1 Problems before the furnace reform 1.1 Problems with the structure of the furnace See the structure of the heat treatment furnace before the modification. The problems of the furnace are as follows.
(a) Schematic diagram of cross section of heat treatment furnace before transformation (>) Schematic diagram of longitudinal section of heat treatment furnace before transformation. Flat six refractory bricks 2. Insulation layer 3. Support bricks 4. Heat-resistant stainless steel threaded pipe 5. Furnace pipe supports refractory bricks 6. The electric heating element furnace has collapse phenomenon. Since two flat and six bricks are lapped in the horizontal direction at the top of the furnace, refractory supporting bricks are required in the middle. The supporting bricks are placed vertically at intervals, and are easily smashed by the heat-resistant stainless steel threaded pipe during production, and even turned over, causing the furnace collapse.
The uniformity of the furnace cross section is poor. Since a row of furnace top support bricks is added in the middle of the furnace, the furnace gas on both sides is not easy to penetrate, and the resistance heat radiation is interpenetrated, resulting in poor uniformity of the furnace temperature of the whole furnace.
The furnace tube supports the refractory bricks to collapse easily. Since the heating element passage and the furnace tube support part are all made of ordinary refractory bricks, in the process of replacing the heat-resistant threaded stainless steel tube, the stainless steel tube easily hits the supporting brick and even knocks over, causing the electric heating element passage to be blocked. It is difficult to replace the heating element.
Poor insulation performance. On the one hand, because the thickness of the insulation layer is thin, the heat preservation effect is not good; on the other hand, the insulation material on the side of the electric heating element is required to be replaced when the electric heating element is replaced, which affects the airtightness of the furnace and is not conducive to the heat preservation of the furnace.
Problems with the electric heating element The schematic diagram of the electric heating element of the furnace before the modification is found to be: the replacement of the electric heating element is not convenient, which is not conducive to maintenance. Every time the electric heating element is replaced, it is necessary to take out a small opening of the furnace, and then pass the U-shaped electric heating element on the wire passage to finally be in place, which not only increases the labor intensity of the maintenance personnel, but also is disadvantageous to the furnace body. Insulation on both sides.
The furnace temperature is poorly uniform. The U-shaped electric heating element is easy to cause a large temperature difference between the furnace terminal and the U-shaped end.
The amount of electric heating element loss is large. Since the length of a single electric heating element is long, once a certain place is damaged, the entire electric heating element is immediately scrapped, and the amount of electric heating material is large.
The flow is beneficial to improve the uniformity of the furnace temperature in the cross section of the furnace.
The original high-alumina refractory brick is used to replace the original ordinary refractory brick, which is used as a bottom electric heating element passage and used as a heat-resistant steel pipe support. Because the material is better, the bottom of the furnace is not easily deformed. Since the furnace bottom of this method is good in integrity, the sealing performance of the furnace is improved. In addition, the upper part of the formed refractory high-alumina refractory brick is processed into a semicircular shape to facilitate the placement of the heat-resistant steel pipe.
The refractory layer and the heat insulation layer on both sides are made of large-sized formed refractory bricks, which can improve the heat preservation effect of the furnace and improve the sealing performance of the furnace.
The insulation layer is made of aluminum silicate fiber cotton with better insulation effect instead of asbestos products, which can also improve the insulation effect.
Considering the unfavorable factors of U-shaped electric heating elements in terms of replacement, furnace sealing, consumables, etc., we use a one-shaped electric heating element with two ends of wiring, the structure and technical requirements are seen. This type of electric heating element replacement is quite convenient, and the temperature asymmetry on both sides of the furnace can be avoided. From the perspective of the use effect, the performance of the in-line electric heating element is superior to that of the U-shaped electric heating element.
3 The effect of the heat treatment furnace after the transformation 3.1 The uniformity of the furnace temperature distribution The furnace temperature before and after the transformation is measured. When the temperature is measured, the probe is deep into the heat-resistant stainless steel pipe outlet at about 1 m. The lateral temperature distribution of the furnace is shown in Table 1. Before and after the modification of Table 1. The furnace temperature distribution is compared with the outlet temperature/°C. After the transformation, it can be seen from Table 1 that the uniformity of the furnace temperature in the cross section is improved after the reforming of the heat treatment furnace, and the maximum temperature difference is reduced from 31*C to 21*C. 3.2. The mechanical properties of the heat-treated steel wire before and after the mechanical properties of the product are shown in Table 2; the heat treatment process parameters are shown in Table 3. Table 2 Mechanical properties of the heat-treated steel wire before and after the transformation Sample wire diameter / average tensile strength / strength dispersion / elongation / number of detection / source It can be seen from Table 2 that the heat treatment furnace has been modified, the strength difference of the steel wire is reduced after the heat treatment, and the elongation rate is improved, which proves that the furnace temperature uniformity of the heat treatment furnace and the heat treatment performance of the steel wire are improved; The finished steel wire produced by the heat treatment furnace is well drawn and tanning.
Manufactured products In June 2001, the development of bearing tubular stranding machine Zhao Shou (Baotou Beiheng Metallurgical Mining Machinery Factory 014040) high speed, automation, and continuous is an inevitable trend in the development of metal products industry at home and abroad, this is in the strand machine The performance in the manufacturing industry is particularly prominent. Professional manufacturers at home and abroad are developing in the direction of large bearing support, bow type machine and double boring machine. The technical equipment level of China's metal products industry has been in a backward state for a long time, and the starting point is low. In the case of a tubular stranding machine, more than 90% of the manufacturers use a roller type. The rope machine has low rotation speed, high noise, fast traction of the supporting wheel, high production cost, inconvenient adjustment and large floor area, and has been basically eliminated in foreign countries.
In view of the problems existing in the original tubular stranding machine, Baotou Beiheng Metallurgical Mining Machinery Factory recently improved and prototyped a batch of GGZ18/300 large bearing tubular stranding machines on the basis of the original equipment.
The main technical parameters of the 18/300 strand rope machine GGZ18/300 is a ramming machine supported by bearings, which is used to control the strands of the wire contact or point contact. The main technical parameters are: steel wire wheel specification: 300mmX release wire wheel specification: 800mmX400mmX470 (3) main body speed: stepless speed regulation, up to 1 table 3 heat treatment furnace before and after transformation process parameters (Korean material) sample source Wire diameter / mm threading number / root heating temperature factory C winding speed / (-min one, import 1 middle 2 export 3.3 insulation and energy saving furnace before and after the insulation and power consumption see Table 4, Table 5. Table 4 Before and after the transformation, the temperature of the outer wall of the furnace is compared with the temperature before the transformation. The temperature before the transformation / the temperature after the transformation of C, the comparison of the power consumption before and after the transformation of Table C / the transformation before the transformation of the root t can be obtained from Table 4, the normal production after the furnace transformation The average outer wall temperature is 51.6*Q and the pre-reformation is 63.4°C. The outer surface temperature of the furnace wall drops by nearly 12°C on average, which proves that the thermal insulation performance after the furnace reform is much better than before the transformation. It can be seen from Table 5 that the furnace is modified every day. The power saving is 608kW -h, and the power saving effect is remarkable.
4 Conclusion Production proves that the heat treatment furnace transformation is successful. Through the transformation, the uniformity of the temperature distribution of the furnace and the uniformity of the mechanical properties of the steel wire are improved, and at the same time, the energy saving effect is obvious.
12-19) Zhou Jiangyi was born in November 1956. He is an engineer and director of the engineering department of Jiangsu Falseng Group.
Xu Ming was born in January 1955, engineer, vice president of Jiangsu Farsh Group.
Wu Qiang was born in October 1967 and is an engineer of Jiangsu Farsheng Group.
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