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Overview
1. General Design Principle and Technical Solutions
The application of reheating furnace meets the production requirements of high production, high quality, low consumption, pollution-free and production automation.
The technical solutions for the design of reheating furnace and its main auxiliary electric & instrument control system ensure the reliable production,advanced indexes, and practical technology.
1.1Technical Solution for Heating Capability
General design principles and technical solutions
The application of reheating furnace meets the production requirements of high production, high quality, low consumption, pollution-free and production automation.
The technical solutions for the design of reheating furnace and its main auxiliary electric & instrument control system ensure reliable production, advanced indexes, and practical technology.
• The theoretical combustion temperature of the fuel is one of the main factors affecting the heating capacity of the furnace. High theoretical combustion temperature of high calorific fuel, high furnace temperature coefficient and high furnace hearth temperature reachable may enhance the heating effect and increase the heating capability of a furnace by increasing the temperature of the furnace hearth. Considering that the project is mainly applied for alloy steel heating, a longer preheating section is required to meet the requirement for low charging temperature and slow temperature rise of alloy steel and thus the strength of the furnace bottom steel is properly taken as a low- value, in which case the effective length of the heating furnace is designed as 24m and bottom strength 347kg/m2·h at the rated output.
• A certain potential shall be considered for the design of heating furnace to meet the heating requirements when rolling the materials of different specifications. In this proposal, the heating load is designed according to maximum cold charging output of 50t/h, and on this basis, 15% extra coefficient is reserved for the burner, leaving adequate capability for increase in production in the future.
• Extra capability of 20% is considered for the design and selection of fans.
• The application of air preheater will preheat combustion air up to ~500°C, which increases the theoretical combustion temperature and helps to increase production.
• The reliable and well-developed automation system ensures the perfectness ratio of combustion system
1.2 Solution for Control of Oxidation Loss
The formation process of scale mainly depends on the furnace atmosphere, furnace temperature and the retention time of billets at high temperature
• Enhancing the burning and mixing of air and fuel is a fundamental measure and furnace atmosphere control is the main way to reduce oxidation loss. Excessive oxygen will promote the oxidation reaction. The operation is too close to the chemical equivalent reaction and will cause the generation of iron scale with stronger viscosity;
• Reasonable distribution of heating load in each section of the heating furnace is the key to lower oxidation burning loss.
• Start by optimizing the distribution of heating load and operating procedures and limit the residence time of the billet surface at a temperature higher than 900°C, that is, operate the furnace according to the output and target discharge temperature, and take strict measures of decreasing heating during the rolling stop;
• Adjust the opening degree of the flue damper rationally for good control of furnace pressure.
• Heating temperature under the heating furnace should not be too low, and it is required to leave enough space for the accumulation of scale.
1.3 Deslagging Solution of Pusher-type Reheating Furnace
The deslagging cycle of heating furnaces is generally 3 to 4 months in China. A furnace is required to shut down for about 1 week for each deslagging, which will cause the suspension of production, the increase of workers' labor intensity, and to some extent influence the service life of the furnace due to frequent start-stop of the heating furnace.
Currently, the deslagging solutions of pusher-type reheating furnaces against the design of the furnace body and its ancillary types of equipment in China are as follows:
• The furnace body is provided with a necessary access door to facilitate the troubleshooting of the furnace and the transportation of furnace slag.
• The side wall in the soaking section is equipped with a necessary manual slag door to facilitate the removal of part of the slag with a shovel without shutting down the furnace.
• Shut down the furnace and clean up the furnace slag manually after the furnace has been operating for a certain period of time.
1.4 Technical Solution to Improve the Heating Quality
• In consideration of the requirements of temperature homogeneity of the roller against billet section and length direction, that is, "low-temperature thorough burning", the heating mode/heating capacity/optimized operating system of the reheating furnace shall necessarily satisfy the requirement. The application of proper furnace type and burners will ensure the quick heating up of the furnace, temperature uniformity of heated billets and low oxidation loss. The improvement in heating quality will also reduce the rolling pressure, the energy consumption of the roller, and potential accidents to some extent.
• The heating furnace is divided into a soaking section and a heating section, with good flexibility.
• Since the lower part of the billets is shielded to a greater extent by the water pipe at the furnace bottom, the heating capacity should be appropriately increased beneath the furnace.
• For temperature homogeneity along with the billet length direction are as follows:
Selection of burner type
layout of burners
location of burners inside of furnace hearth
Furnace hearth pressure control and emission
• Temperature deviation between surface and center is as follows:
Sufficient heat in the heating zone
The reasonable heating time of the billet inside the furnace
To determine the length of the soaking section for better soaking.
1.5 Energy Saving Measures
The application of inserted tube-type metallic heat exchanger will preheat the air temperature up to ~500°C, which may have a significant energy-saving function.
• Preheating section shall be reserved as long as possible under the condition that production output is guaranteed.
• Low cement heavy-weight castable is applied for the overall pouring of the working face; a composite structure is applied for the furnace top/bottom/wall to minimize heat loss of the furnace body.
• Optimize the furnace door and make the structural design for flexible opening and tight sealing to reduce the heat loss from furnace gas overflow and cold air intake.
Company Profile
| Professional Professional technical and management team with abundant experience in the implementation of domestic and international projects; |
| Responsive Responsively and meticulously, translating your needs into complete solutions; |
| Integration Integrating various technologies and resources in China and fulfilling complementary advantages, by relying on professional teams; |
| Motivation Motivated to provide the optimal solution and quality products; |
| Exceptional Exceptional, delivery and,implementation of projects to meet, your expectations; |
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